OUSD (R&E) MODERNIZATION PRIORITY: General Warfighting Requirements (GWR) TECHNOLOGY AREA(S): Electronics; Materials; Air Platform OBJECTIVE: State-of-the-art large structural composite manufacturing includes the use of thermocouples to monitor temperature ramp rates and steady state temperature profiles to ensure correct cure cycles. These data streams are expected to become more prolific and denser as current research and development is addressing wireless, in-the-bag thermocouple technologies that will make temperature data collection more convenient and affordable. Yet despite the wealth of data available, it is rarely used for anything more than to ensure temperature profiles are within tolerance; it is then archived (typically on a hard drive somewhere) and forgotten unless there is an investigation related to a future component failure. The objective of this project is to maximize the value of this data by using it to accomplish some or all of the following: optimize manufacturing processes; optimize workpiece properties; enable model-based quality definition and/or serial-number-specific part certification; enhance agility; and enable rapid spin-up of production capacity for aerospace components. DESCRIPTION: Research and develop a general and reusable technology stack (methods, algorithms, tools, software, etc.) for collecting, managing, curating, and using thermocouple data collected in composites curing processes. Develop data pipelines that facilitate the integration of temperature data collection systems, digital models, and product lifecycle management tools, preferably based on current standards. Develop technology that utilizes thermocouple data to enable adaptive process control to optimize manufacturing processes. Process optimization includes classical metrics like yield, cycle time, tolerances, and process capability, but can also include optimization of the process to maximize material property objectives. Tools that optimize or facilitate agile decision making for upstream and/or downstream manufacturing processes, possibly across links in the supply chain, are also encouraged. Develop technology leverages temperature data to enable model-based inspection and serial-number-specific workpiece quality inspection and certification. Develop technology that enables supply chain agility by allowing aerospace manufacturers to quickly and confidently spin up production of novel components. Solutions that facilitate rapid adaptation of non-aerospace to emergency aerospace production is also encouraged. Cloud-based solutions are encouraged, but the Department of Defense's cybersecurity needs must be adequately addressed. Proposals that include technology demonstrations and/or pilot systems in production at aerospace manufacturers are highly encouraged. 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 and development, or direct procurement of products and services developed in coordination with the program. REFERENCES: Singh, Rashmi; Singh, S.P., Development of a Low Cost Wireless Temperature Monitoring System for Industrial & Research Application , International Journal of Current Engineering and Technology, February 7, 2015,Vol. 5, No.1(Feb 2015); School of Energy and Environmental Studies, Devi Ahilya University, Khandwa Road, Indore 452001, India; Arnold, F.; DeMallie, I.; Florence, L., Kashinski, O., Method for collecting thermocouple data via shell over a wireless local area network in real time , Rev. Sci. Instrum. 86 035112 (2015), March 7, 2015, Photonics Research Center, United States Military Academy, West Point, New York 10996, USA; Nicolay, Pascal; Naumenko, Natalya, Optimal design for an innovative very-high-temperature hybrid SAW Sensor , IEEE International Ultrasonics Symposium, IUS, October 31,2017, 2017 IEEE International Ultrasonics Symposium, IUS 2017; ISSN: 19485719, E-ISSN: 19485727;ISBN-13: 9781538633830; DOI: 10.1109/ULTSYM.2017.8091550; Article number: 8091550; Conference:2017 IEEE International Ultrasonics Symposium, IUS 2017, September 6, 2017 - September 9, 2017;Publisher: IEEE Computer Society; Nicolay, P.; Matloub, R.; Bardong, J.; Mazzalai, A.; Muralt, P., A concept of wireless and passive very-high temperature sensor , Applied Physics Letters, v 110, n 18,May 1, 2017; ISSN: 00036951; DOI: 10.1063/1.4983085; Article number: 184104; Publisher: American Institute of Physics Inc.; Patra, Dibyayan; Kundu, Chitresh; Patra, Prabal, Wireless Dip Temperature Lance for provisioning hot metal analytics of blast furnaces , Ironmaking and Steelmaking, v 48, n 5, p 619-627,2021; ISSN: 03019233, E-ISSN: 17432812; DOI: 10.1080/03019233.2020.1833677; Publisher: Taylor andFrancis Ltd.; KEYWORDS: thermocouple; hub; reciever; temperature; cure; composite; out of autoclave; composite aircraft; manufacture; defect; repair; damage; porosity; delamination
