Level 2 (Self)
TECHNOLOGY AREAS
None
MODERNIZATION PRIORITIES
Mission Readiness & Disaster Preparedness
|
Nuclear
|
Sustainment & Logistics
KEYWORDS
Batteries, Battery Technology, Non-Lithium Battery, Military Logistics, Field Operations
OBJECTIVE
Develop and demonstrate a
non-lithium battery cell and/or prototype battery pack
capable of supporting BB-2590/U-class applications, with emphasis on safety, transportability, and domestic manufacturability, while achieving
mission-relevant performance thresholds
.
DESCRIPTION
DLA's current battery portfolio, including the widely fielded BB-2590/U rechargeable battery (NSN: 6140-01-490-4316), relies heavily on lithium-ion chemistries with significant exposure to foreign (including Chinese-origin) supply chains. Section 154 of the FY2024 NDAA restricts DoD procurement from certain foreign sources beginning in October 2027, creating an urgent need for compliant alternatives.
Beyond supply chain risk, lithium-based batteries present operational challenges including hazardous material classification for transport, thermal runaway risks, limited long-duration storage performance, and handling complexity in forward-deployed environments.
DLA requires a non-lithium battery solution that can support BB-2590/U-class applications while improving:
Safety: Reduced or eliminated thermal runaway risk
Transportability: Less restrictive hazardous material classification and simplified logistics handling
Storage Readiness: Low self-discharge and long-duration storage ( 12 24 months)
Operational Performance: Reliable function across -30 C to +60 C environments
Durability: Resistance to shock, vibration, and field conditions
Supply Chain: Fully domestic or NDAA-compliant sourcing
Solutions may not need to exceed lithium-ion performance in all areas but must demonstrate clear operational advantages in safety, logistics, or sustainment.
Performance Targets:
Proposed solutions should aim to meet or approach:
Energy Density: 150 Wh/kg (threshold), 200 Wh/kg (objective)
Cycle Life: 500 cycles to 80% capacity
Storage Life: 12 months with minimal degradation
Operating Temperature: -30 C to +60 C
Safety: No thermal runaway under standard abuse conditions
Transport: Reduced hazardous classification compared to Li-ion (if applicable)
MIL-STD environmental qualification testing covering temperature, vibration, and mechanical shock
Preliminary safety qualification aligned with MIL-PRF-32383/3
Validated domestic bill of materials demonstrating NDAA-compliant manufacturability
Commercialization plan and domestic manufacturing roadmap with cost-per-unit projections at production volume
Scope
Phase I (6 months, up to $100K)
Focus on
cell-level feasibility and trade-space validation
:
Demonstrate a
non-lithium electrochemical system
with initial performance data
Characterize:
Energy density (Wh/kg, Wh/L)
Cycle life projections
Voltage profile and discharge characteristics
Temperature performance
Conduct
preliminary safety testing
, including abuse tolerance
Perform
storage/self-discharge testing
Provide:
Concept for integration into BB-2590/U-class form factor
Initial domestic supply chain assessment
Phase II development plan
Phase II (18 months, up to $1M)
Focus on
prototype demonstration and transition readiness
:
Develop a
prototype battery module or pack
aligned with BB-2590/U electrical requirements
Conduct:
Environmental testing (temperature, shock, vibration)
Extended cycle and storage validation
Safety characterization aligned with military battery standards
Deliver:
Prototype system demonstration
Validated domestic Bill of Materials
Manufacturing feasibility and cost model
Transition plan including pathway to qualification and DLA procurement
PHASE I
Phase I Deliverables (up to 6 months, up to $100,000)
The Phase I effort will establish the core technical feasibility of the proposed non-lithium battery chemistry through systematic cell characterization and safety testing. The following deliverables are expected:
Electrochemical Characterization: Prototype cells at a relevant form factor shall be characterized and tested, with performance data reported for energy density in Wh/kg and Wh/L, cycle life to 80% capacity retention, nominal voltage, and operational temperature range across both cold and high-heat conditions.
Safety Testing: Thermal stability characterization shall be conducted to demonstrate the absence of thermal runaway response under representative charge, discharge, and abuse conditions, establishing the fundamental safety advantage of the proposed chemistry over conventional lithium-based systems.
Self-Discharge Assessment: A storage stability assessment shall be conducted to measure self-discharge rates over a defined period, providing quantitative data to evaluate the technology's potential for reducing infrastructure overhead associated with long-term DLA war-reserve and pre-positioned stock storage.
PHASE II
Phase II Deliverables (18 months, up to $1,000,000)
Building on the Phase I feasibility demonstration, Phase II will advance the technology to a battery pack level and generate the qualification and commercialization data required for DLA procurement consideration. The following deliverables are expected:
Scaled Battery Pack Prototype: A fully integrated battery pack prototype shall be developed meeting the form factor and electrical specifications of target DLA battery applications, demonstrating the scalability of the Phase I cell technology to a system-level configuration.
MIL-STD Environmental Testing: The prototype shall be subjected to MIL-STD environmental qualification testing covering operational temperature performance and mechanical vibration, demonstrating suitability for deployment across diverse military platforms and environments.
Preliminary Safety Qualification: Safety qualification data shall be generated in alignment with applicable MIL-PRF specifications, providing DLA and its program offices with a preliminary compliance baseline for procurement and fielding consideration.
Validated Bill of Materials: A validated bill of materials shall be developed demonstrating the domestic manufacturability of the battery system, supporting DLA's interest in building a resilient and accessible domestic supply base for next-generation battery technologies.
Commercialization Plan and Manufacturing Roadmap: A detailed commercialization plan and domestic manufacturing roadmap shall be delivered, including cost-per-unit projections at production volume, outlining the pathway for transitioning the technology from prototype to DLA-procurable supply item and broader commercial markets including heavy-duty vehicle electrification, maritime autonomous systems, and stationary grid-scale energy storage.
PHASE III DUAL USE APPLICATIONS
This technology has strong dual-use potential across both defense and commercial markets.
Defense Applications:
Man-portable communications systems
Unmanned systems (UGV/UAS)
Expeditionary sensors and electronic warfare systems
Pre-positioned war reserve energy storage
Commercial Applications:
Industrial and warehouse robotics
Remote sensing and IoT systems
Medical and safety-critical portable devices
Backup and stationary energy storage systems
Maritime and off-grid energy solutions
The emphasis on safety, long storage life, and simplified logistics positions non-lithium technologies as attractive alternatives in markets where lithium-ion risks or transport constraints are limiting factors.
REFERENCES
National Defense Authorization Act for Fiscal Year 2024, Pub. L. No. 118-31, 154, 137 Stat. 136, 163 164 (2023).
congress.gov https://www.congress.gov/bill/118th-congress/house-bill/2670/text
Federal Consortium for Advanced Batteries. (2021, June). National blueprint for lithium batteries 2021 2030. U.S.
Department of Energy. energy.gov https://www.energy.gov/sites/default/files/2021-06/FCAB%20National%20Blueprint%20Lithium%20Batteries%200621_0.pdf
U.S. Department of Defense. (2011). MIL-PRF-32383/3: Performance Specification Sheet: Battery, Rechargeable, Sealed, BB-2590()/U, BB-390()/U, and BB-3590()/U. ASSIST-QuickSearch.
https://assistca.dla.mil/online/doc_analysis/doc_info_general.cfm?ident_number=277791
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