Materials

PE 0602102F: Materials is a Research, Development, Test & Evaluation (RDT&E) program element managed by the Air Force Research Laboratory (AFRL) under Budget Activity 2: Applied Research. The overarching goal of this program is to develop advanced materials, processing, and inspection technologies that reduce life cycle costs and improve the performance, sustainability, reliability, and survivability of current and future Department of the Air Force (DAF) systems. The program supports high-impact, multi-domain science and technology solutions that address key DAF priorities, including air, space, and cyber domains. Funding also supports the civilian workforce required to manage and deliver these capabilities, with direct Full-Time Equivalent (FTE) civilians budgeted for FY 2026.

Materials for Structures, Propulsion, and Subsystems focuses on developing and transitioning materials and processing technologies to enhance the affordability, maintainability, and performance of Air Force weapon systems. Specific objectives include the advancement of lightweight metals, polymers, ceramics, composites, and hybrid materials for aircraft, spacecraft, missiles, and propulsion systems. Efforts target improved ablation and oxidation resistance, structural integrity, thermal management, and strength-to-weight ratios. The project also develops advanced processing methods, including additive manufacturing and powder processing, to address obsolescence challenges and reduce reliance on traditional supply chains. Congressional adds in recent fiscal years support accelerated material development for high-mach capabilities, scaling titanium additive manufacturing, advanced composites for hypersonics, and thermal protection for hypersonic vehicles.

Materials for Electronics, Optics, and Survivability aims to develop materials technologies for Intelligence, Surveillance, and Reconnaissance (ISR), situational awareness, and specialty coatings for aerospace platforms and munitions. The project includes research on electronic and optical materials for sensors, countermeasures, and active aircraft protection, with goals of achieving faster operating speeds, higher power output, improved thermal management, and greater sensitivity. Efforts also focus on materials for electromagnetic protection, including coatings and metasurfaces to defend against directed energy threats. Biological materials research is directed toward biomanufacturing, biotechnology, and the development of agile materials for basing and infrastructure. Congressional adds have supported synthetic biology manufacturing, nano-bio technologies, composites for electromagnetic interference shielding, and next-generation small satellite technologies.

Materials Technology for Sustainment develops materials and processing technologies to support operational mission areas by enabling inspection, transition of reliable materials, defect detection, and failure analysis. The project emphasizes non-destructive inspection/evaluation (NDI/E) methods for metallic and non-metallic structures, coatings, and corrosion control processes, which are essential for monitoring aging systems and ensuring quality in design and production. Key objectives include advancing material state awareness technologies, developing affordable survivability materials and processes, and enhancing failure analysis and mishap prevention capabilities. Efforts are directed at improving readiness, reducing maintenance actions, and increasing the availability of fielded systems. Congressional support has included multi-functional protective materials for enhanced survivability.

Across all projects, the program leverages computational materials science, artificial intelligence, and machine learning to accelerate material development, characterization, and certification. The use of advanced modeling tools enables faster qualification of new materials and supports the transition of technologies from research to operational systems. The program also prioritizes collaboration with manufacturing innovation institutes and consortia to accelerate domestic biomanufacturing and advanced materials development.

Program funding adjustments in FY 2026 reflect strategic realignment to optimize research areas and improve resource efficiency, including reductions for civilian personnel and advisory services in compliance with executive orders on government efficiency. Congressional adds have provided targeted increases for specific technology advancements, while other adjustments have reallocated funds to support laboratory enhancements and workforce optimization. The acquisition strategy for these projects is primarily focused on research and technology development, with no direct procurement or system acquisition activities.