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: Develop new oriented film based materials with superior ballistic performance, good durability, manufacturability, and cost competitive to currently fielded ballistic fibers and fabrics. DESCRIPTION: In recent years, advances in polymer processing science and technology have enabled the development of highly oriented polymer films with mechanical properties that significantly exceed previous materials made with the same base polymer. Advances have been made in producing and drawing films from difficult-to-process polymers with exceptional properties, such as ultrahigh molecular weight polyethylene. These materials have already advanced the state of protective soldier protective systems, such as with the development of the advanced combat Helmet Gen II.1 In addition to achieving preferential orientation of base polymers, researchers have demonstrated formation of nanocomposite films with exceptional properties. Optimization of film processing parameters can be greatly aided by laboratory techniques that allow better fundamental understanding of the structural evolution of polymer films during post-stretching processing; recent advances in synchrotron radiation (SR) light sources and detection techniques allow measurement of the polymer's changing morphology in real time with the use of a combination of small- and wide-angle X-ray scattering (SAXS/WAXS). These studies can be used to create process-structure-property databases that can be used as the basis for model discovery and combined with artificial intelligence techniques to rapidly converge on optimal processing conditions, rather than using traditional trial and error techniques.2 There are compelling indications that oriented films may provide superior ballistic performance to oriented fibers made of the same polymer. Around 2007, several manufacturers began producing a solid state extruded film made from ultrahigh molecular weight polyethylene. The ballistic performance of this film was noted to be higher than expected given its low tensile strength relative to its ultrahigh molecular weight polyethylene fiber counterpart (3,4). Oriented films such as uniaxially oriented polypropylene have also shown promise for transparent armor.5 The technical challenge of meeting optical transmittance and clarity requirements for transparent armor while providing a high level of ballistic protection is much more significant than for opaque armor. Thus, transparent oriented films with improved ballistic performance are of particular interest in this topic. PHASE I: Phase I of the program should demonstrate feasibility of the technical approach and development of the initial material concept. Offerer will select materials for candidate films and explore processing mechanisms for creating oriented films with superior properties. Materials can include base polymers as well as additives. The focus of Phase I is to demonstrate the ability to enhance the properties of the base polymer film through processing and use of additives. Measurements to characterize the film material's morphology and correlate it to processing conditions and to mechanical properties should be performed in Phase 1. Technologies will be evaluated for transition to Phase II based on improved tensile strength and modulus values. U* may also be used to evaluate performance advancement. 6 PHASE II: Phase II should focus on material production to generate prototypes for ballistic evaluation. The PI will develop materials and processes to fabricate ballistic flat panels at areal densities from about 0.5 pounds per square foot (psf) up to about 1.0 psf. At a minimum, materials for opaque armor should be tested for V50 against 17 grain fragment simulating projectile (FSP). Transparent materials should be tested for transmissivity, haze, scratch resistance, and V50 against 17 grain and 5.8 grain fsp (0.125 inch thich samples). Final deliverables should include a cost estimate for scale up and production of the material, technical data package, prototypes for evaluation by the Government and a final report. PHASE III DUAL USE APPLICATIONS: Phase III should focus on scale up of the material product and building prototype components to demonstrate appropriate applications of the material. For opaque armor, prototype components could include helmets and/or ceramic plate armor backings. Lenses or visors should be the focus for transparent material applications. While the animus for this topic is improved ballistic protection at the dismounted soldier level, the technology may be extrapolated for broader military use. Improved materials may also be of commercial interest for non-DoD protective and security services. REFERENCES: 1. https://www.military.com/daily-news/2017/03/30/army-shows-off-its-lightest-combat-helmet-ever.html; 2. Kim, Jun Young, Carbon Nanotube-Reinforced Thermotropic Liquid Crystal Polymer Nanocomposites , Materials 2009, 2, 1955-1974; 3. University of Warwick. "Polythene films strong as aluminum could be used for windows, screens and phones." ScienceDaily. ScienceDaily, 1 April 2019. https://www.sciencedaily.com/releases/2019/04/190401121817.htm; 4. Singletary, J. and B. Lauke, Polyolefin film reinforced composites for personal protection in Advanced Fibrous Composite Materials for Ballistic Protection, 2016; 5. Yunyin Lin, Ruhi Patel, Jun Cao, Wei Tu, Han Zhang, Emiliano Bilotti, Cees W.M. Bastiaansen, Ton Peijs. Glass-like transparent high strength polyethylene films by tuning drawing temperature. Polymer, 2019; 171: 180 DOI: 10.1016/j.polymer.2019.03.036; 6. Yuanfei Lin, Wei Chen, Lingpu Meng,a Daoliang Wanga and Liangbin Li Recent advances in post-stretching processing of polymer films with in situ synchrotron radiation X-ray scattering , Soft Matter, Issue 15, 2020 KEYWORDS: Ballistic materials, oriented polymer films, nanocomposites, transparent armor, ballistic eyewear
