Dynamic Materials for Customizable Impact Protection

OUSD (R&E) MODERNIZATION PRIORITY: General Warfighting Requirements (GWR) TECHNOLOGY AREA(S): Space Platform; Materials; Battlespace OBJECTIVE: To develop novel reconfigurable thermoset composite panels with excellent impact resistance. The materials will preferably be able to be reshaped to demonstrate the ability to protect structures such as aircraft underbodies, vehicle doors & undercarriage and Airmen. Additionally, composites should be able to demonstrate on-site panel welding and repair after impact while also meeting current state of the art ballistic needs. DESCRIPTION: The goal of this SBIR is mature and demonstrate a transformational concept that fundamentally shifts the defense economy from a static single component to a dynamic continuous fabrication mentality to meet 21st century defense needs. This concept would lead to significant cost savings as well as unprecedented agility. While traditional materials are often shipped to locations in end use shapes & configurations, and act as single use components, this project will focus on emergent materials that enable reconfigurable components. Specifically, concepts stemming from materials including (but not limited to), reprocessable thermosets, covalent adaptable networks, and self-healing polymers may offer reconfigurability while maintaining durability. Reprocessable thermoset composites exhibit excellent material strength & resilience but offer significant advantages over conventional thermoplastic & thermosets including the new ability for polymer bonding, reshaping & repair. These materials, or composites, should focus on: 1) Exhibiting excellent mechanical properties while being chemically active , to facilitate on-site material reprocessing. 2) Illustrating the ability to ship flat components (or other easily shipped shapes) and then reshape, or weld, materials into the desired configuration for on-site use as lightweight ballistic protection for aircraft, vehicles, or personnel. 3) Make significant effort to minimize complex tooling/processing to reshape the materials so on-site protocols can be performed in a straightforward manner. This concept would facilitate comprehensive on-site repair of damaged components and provides inherent advantages for expeditionary forces to sustain operations in austere locations and expeditionary bases. PHASE I: This topic is intended for technology proven ready to move directly into a Phase II. Therefore, a Phase I award is not required. The offeror is required to provide detail and documentation in the Direct to Phase II proposal which demonstrates accomplishment of a Phase I-like effort, including a feasibility study. This includes determining, insofar as possible, the scientific and technical merit and feasibility of ideas appearing to have commercial potential. It must have validated the product-market fit between the proposed solution and a potential AF stakeholder. The offeror should have defined a clear, immediately actionable plan with the proposed solution and the AF customer. The feasibility study should have; -Identified the prime potential AF end user(s) for the non-Defense commercial offering to solve the AF need, i.e., how it has been modified; -Described integration cost and feasibility with current mission-specific products; -Described if/how the demonstration can be used by other DoD or Governmental customers. PHASE II: Eligibility for D2P2 is predicated on the offeror having performed a Phase I-like effort predominantly separate from the SBIR Programs. Under the phase II effort, the offeror shall sufficiently develop the technical approach, product, or process in order to conduct a small number of advanced manufacturing and/or sustainment relevant demonstrations. Identification of manufacturing/production issues and or business model modifications required to further improve product or process relevance to improved sustainment costs, availability, or safety, should be documented. Air Force sustainment stakeholder engagement is paramount to successful validation of the technical approach. These Phase II awards are intended to provide a path to commercialization, not the final step for the proposed solution. PHASE III DUAL USE APPLICATIONS: The contractor will pursue commercialization of the various technologies developed in Phase II for transitioning expanded mission capability to a broad range of potential government and civilian users and alternate mission applications. Direct access with end users and government customers will be provided with opportunities to receive Phase III awards for providing the government additional research & development, or direct procurement of products and services developed in coordination with the program. REFERENCES: Taynton, P.; Ni, H.; Zhu, C.; Yu, K.; Loob, S.; Jin, Y.; Qi, J.; Zhang, W. "Repairable Woven Carbon Fiber Composites with Full Recyclability Enabled by Malleable Polyimine Networks" Adv. Mater. 2016, 28, 2904 2909 KEYWORDS: Agile; repair; reconfigurable components; self-healing; adaptable networks; composites; polymer welding.