Advanced Manufacturing of Cryocoolers for Infrared IR sensors

TECHNOLOGY AREAS: Sensors The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 3.5 of the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. OBJECTIVE: This topic seeks to mature manufacturing processes for Infrared (IR) Cryogenic Coolers (cryocoolers). Ideal projects would improve the quality of the cryocooler and drive down cost through increased production, increased reliability, and development of a manufacturing process enhancement model capable of component/subcomponent design, predictive manufacturing processes and tracking of manufacturing process data. DESCRIPTION: The Department of the Air Force and U.S. Space Force needs effective, reliable, low-cost IR cryocoolers to cool down infrared detectors down to cryogenic temperatures to perform within desired specifications. Cryocoolers are the components that provide the cryogenic cooling capability; currently they're designed by custom, fabricated, and qualified in low numbers at large costs (e.g. $3-5 million per unit). Currently cryocoolers are provided by large prime contractors or sourced via foreign suppliers. This effort should implement existing manufacturing processes to increase production and inspect the feasibility of cost reduction to less than $1 million per unit. It should also investigate advanced manufacturing techniques to further reduce costs to at most $250 thousand per unit and increase rate of production to at least 50 units per year. This should be done while meeting performance specifications of cooling, size, weight, power, meant-time-to-failure and vibration. PHASE I: This topic is intended for technology proven ready to move directly into a Phase II effort. Therefore, a Phase I award is not required. The applicant is required to provide detail and documentation in the Direct to Phase II (D2P2) proposal which demonstrates accomplishments of a Phase I- type effort including a feasibility study. This includes determining the scientific and technical merit and feasibility of ideas appearing to have to have commercial and/or defense potential. The applicant must demonstrate that a prototype infrared cryocooler manufacturing capability exists or provide modeling capability to support a design. The applicant should have a clearly defined actionable plan with proposed solution and AF customer and should be able to describe how/if the capability can be used by other DoD or Government customers. PHASE II: Eligibility for D2P2 is predicated on the applicant having performed a Phase I-type effort predominantly separate from the SBIR/STTR programs. Under the phase II effort, the applicant shall optimize previous designs of cryocoolers for manufacturing. The applicant shall sufficiently develop the technical approach and manufacturing processes to fabricate and test a small number of relevant prototypes. Relevant process steps shall be detailed including but not limited to assembly techniques, work instructions and build of materials. Identification of manufacturing/production issues and or business model modifications required to further improve process and product should also be documented. A successful phase II effort will utilize components and manufacturing processes that increase production yields and improve capabilities of companies to become suppliers of cryocoolers to DoD prime contractors. Cryocoolers of interest will be able to meet the following objectives: - Up to 2.5 Watts of cooling at 71 degrees Celsius - Operating temperature -40 degrees Celsius to 71 degrees Celsius - Noise, Root Mean Square less than or equal to 1 peak-to-peak voltage PHASE III DUAL USE APPLICATIONS: Commercialize the new approach by supplying subcomponents to cryocooler integrators, by supplying equipment to cryocooler manufacturers, or by manufacturing cryocoolers in-house. Begin producing and delivering products, at a low rate, to customers. Fully qualify the product for the intended application(s). Assist in integrating the product into a demonstrator system REFERENCES: 1. CREARE LLC, Low Temperature, Low Capacity Cryocooler Technology, NASA SBIR phase I, July 2023 February 2024; https://www.sbir.gov/awards/204145 2. CREARE LLC, Low Cost Radiation-Hardened Cryocooler Control Electronics for Space Missions, NASA SBIR Phase II, June 2023 June 2025; https://www.sbir.gov/awards/204151 3. WECOSO INC, Miniature 2-Stage 20k Cryocooler, NASA SBIR phase I, July 2023 February; https://www.sbir.gov/awards/204238 4. QMAGIQ LLC, DEPOSITION OF MULTIPLE INFRARED SPECTRAL FILTERS DIRECTLY ON FOCAL PLANE ARRAY , NASA SBIR phase I June 2022 - Jan 2023; https://www.sbir.gov/awards/196178 5. TRITON SYSTEMS INC, High-Efficiency Modified Collins Cycle Cryocooler, NASA SBIR phase I Jul 2022 jan 2023; https://www.sbir.gov/awards/196501 KEYWORDS: Cryocooler; Manufacturing; space