Scalable Agile Manufacturing of Launched Effects

KEYWORDS
Launched Effects, Airframe Manufacturing, High-rate Production
OBJECTIVE
The objective of this topic is to demonstrate mass production of launched effect airframes at high rates (objective: 10,000 / month) and low cost (objective: $2,000) while also quickly accommodating design changes.
DESCRIPTION
Uncrewed aircraft systems (UAS) are expected to play an increasingly significant role on the future battlefield. Launched Effects (LEs) are UAS launched from a tube either from air or ground platforms and can perform a variety of missions. The attritable or optionally recoverable nature and desire for swarming of LEs means the Army will need large numbers of them produced at high rates and for low cost, and a rapidly changing battlefield will require an agile manufacturing process.
Current airframe manufacturing approaches that use high-performance carbon fiber composite material are challenged by high material costs, long lead times on tooling, labor-intensive fabrication techniques, scaling challenges.
This topic seeks to develop and demonstrate mass-manufacturing approaches for LE airframes that retain high structural efficiency and sufficient capability to operate in demanding environments. The total cost of the assembled airframe (which includes skins, stiffening elements, frames, control surfaces, bulkheads, clips, brackets, and other structural features but does not other non-structural systems) is desired to be $2,000, and the desired maximum production rate is 10,000 vehicles per month. Additionally, the manufacturing process should be modular and adaptable such that it is able to adjust to a minor design change rapidly in a matter of hours or days.
Proposals should provide an overview of the entire manufacturing approach with enough detail to substantiate that the proposer has considered all pertinent aspects of the design, such as critical interfaces, space, weight and power allocations, assembly constraints, and manufacturing limitations. Considerations are expected to include balancing fabrication of components with assembly into a full airframe and may include automated techniques. LE designs should be structurally representative, and the effort should present a baseline vehicle performance to be compared to the final design performance.
PHASE I: The outcome of Phase 1 is expected to be a representative LE design and feasibility study that details how the proposed manufacturing approach achieves the desired rate, cost target, and design modularity and ability to adapt to design changes. The manufacturing approach should include fabrication and assembly processes that are already matured or sufficiently mature such that negligible development is needed during Phase 2; fabrication and assembly processes requiring significant development before they could be implemented are not desired. Documentation from prior efforts that supports the analyses used in the feasibility study is encouraged. Small-scale feasibility demonstrations may also be conducted.
PHASE I
This topic is accepting Phase I submissions for a cost limit up to $300,000 and a 1-6-month period of performance.
The outcome of Phase 1 is expected to be a representative LE design and feasibility study that details how the proposed manufacturing approach achieves the desired rate, cost target, and design modularity and ability to adapt to design changes. The manufacturing approach should include fabrication and assembly processes that are already matured or sufficiently mature such that negligible development is needed during Phase 2; fabrication and assembly processes requiring significant development before they could be implemented are not desired. Documentation from prior efforts that supports the analyses used in the feasibility study is encouraged. Small-scale feasibility demonstrations may also be conducted.
PHASE II
In Phase 2, firms are expected to refine their design and manufacturing approach and conduct a manufacturing demonstration that substantiates the ability to make at least 80 articles in one week and incorporates one design change in the process. The final report shall include a detailed technical data package that documents the manufacturing processes with sufficient detail to justify the cost, manufacturing rate of 10,000 per month, and design adaptation targets.
PHASE III DUAL USE APPLICATIONS
The LEs manufactured using this technology can have non-military uses, such as surveillance and communication during emergency response, guarding secure installations, and border protection.
The manufacturing capability can be used to mass-produce UAS for many commercial applications, such as package delivery, agriculture, infrastructure inspection, and mapping.
REFERENCES
U.S. Army Taps Three Companies for Cutting-Edge Launched Effects Demonstration, March 27, 2025, https://www.army.mil/article/284204/u_s_army_taps_three_companies_for_cutting_edge _launched_effects_demonstration