Far Forward Manufacturing of CBRN Sensors

OBJECTIVE
Accelerate Far Forward Manufacturing (FFM) of Chemical, Biological, Radiological, and Nuclear (CBRN) sensors. CBRN sensor products should be minimal size, weight, and power economic, while detecting and transmitting threat awareness in near real-time to the warfighter. The ability to create these devices on-demand and with limited logistical footprints will enable global operations and critical real-time data ingestion.
DESCRIPTION
The Department of Defense is looking for FFM of robust CBRN sensors that require limited logistical footprints. This topic seeks capabilities that shift reliance away from protracted and/or brittle supply chain dependencies and towards faster, more efficient, and point-of-need (e.g., Far Forward) manufacturing of CBRN sensing capabilities.
Advanced manufacturing approaches have made significant gains in consolidating assemblies, resource conservation (weight and material savings), increased customization, and accelerated design-test and-iteration processes1, exponentially shrinking the time from prototype to field assessment and realization of capabilities2. Embracing this, the Army is currently exploring significant acceleration in the production of 3D-printed drones to boost training efforts for modern warfare3. Similarly, the rapidly changing nature of modern warfare necessitates capabilities to help warfighters avoid contamination and provide increased decision space to assess mitigation strategies. CBRN sensing products manufactured and scaled on-site, at low cost, to detect and provide near real-time awareness of CBRN threat exposure is critical to ensuring force readiness and adaptability.
The Chemical and Biological Defense Program (CBDP) aims to explore FFM approaches that will enable speed and scale of CBRN sensing technologies that have minimal size, weight, power economy, logistical burden, and sustainment costs. Innovative approaches may include, but are not limited to: fused filament fabrication, fused deposition modeling, selective laser melting, direct metal laser sintering, and biomanufacturing.
PHASE I
Demonstrate proof of concept. Phase I will demonstrate proof of concept (POC) of FFM of a functional CBRN sensor that (1) detects the presence of any single chemical, biological, or radiological threat, (2) indicates human safety vs. hazard levels (3) detect within 5 minutes, and (4) ensures the total manufacturing footprint can be packaged in less than 1 CONEX box (20 ft wide, 40 ft long). Phase I will also provide documentation detailing: sensor design specifications, sensor performance (e.g., specificity and sensitivity), sensor platform plasticity (e.g., breadth of threat detection), sensor product process development, downstream processing steps (if necessary), defense and commercial (e.g., dual-use) business plan, and a clear plan to achieve success in Phase II. Preference may be given to proposals that can achieve POC within a 4-month period of performance (POP).
PHASE II
PHASE II: Far Forward Manufacturing Prototype. Phase II will finalize the processes (e.g., process parameters, automation, quality systems) necessary for production of their sensor product and demonstrate a production run no longer than 24hrs with an output of no less than 20 sensing products capable of detecting and indicating a CBRN threat (safe vs hazardous level). Phase II will also provide proof-of-concept shelf-life assessments (for FFM, and sensor products), voice of end user surveys capturing feedback, and a revised business model for both commercial and defense markets. 12-to-18-month PoP.
PHASE II Enhancements: To further encourage the transition of research into DoD acquisition programs as well as the private sector, the CBD SBIR/STTR Program may provide a Phase II awardee (the initial Phase II or a Sequential Phase II) with up to $500,000.00 in matching SBIR funding (on a dollar-for-dollar basis) if the performer obtains commitment of non-SBIR/STTR funding from a DoD component(s), Federal Agency(ies), and/or a commercial investor(s). Enhancement funding is typically applied to an active Phase II award via a contract modification and will result in an additional period of performance that is commensurate with the total funding received, typically 6 to 18 months (18 months being the maximum). The proposed Enhancement effort must develop, deliver, and integrate a technology or product into a program within a DoD component(s), Federal Agency(ies), and/or the commercial sector.
PHASE III DUAL USE APPLICATIONS
PHASE III: Phase III will involve end user (warfighter) feedback to align targets of sensing interest, sensor sensitivity and selectivity, and manufacturing engineering runs for end user utility and adoption.
PHASE III DUAL USE APPLICATIONS: Outside of the DoD, CBRN sensor products are invaluable tools for commercial sectors such as clinical diagnostics, environmental sensing, and agricultural / food screening.
REFERENCES
https://www.dau.edu/library/damag/july-august2021/additive-manufacturing
https://amchronicle.com/insights/why-has-am-been-able-to-move-from-prototyping-to-production/
https://thedefensepost.com/2025/04/15/us-army-3d-drones/
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