JOFOC Spirit_Final_Redacted for posting_9_26_24.pdf

NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

GLENN RESEARCH CENTER (GRC)

JUSTIFICATION FOR OTHER THAN FULL AND OPEN COMPETITION

(JOFOC)

For Fabrication of Composite Coupons, Subcomponent, and Constituent Materials

1. Federal Acquisition Regulation (FAR) 6.303-2(b)(1) – Identification of the agency and the contracting activity, and specific identification of the document as a “Justification for other than full and open competition.”

This document is a justification for other than full and open competition prepared by National Aeronautics and Space Administration (NASA) Glenn Research Center.

The procuring agency is the National Aeronautics and Space Administration (NASA), and the contracting activity is Glenn Research Center.

2. FAR 6.303-2(b)(2) – The nature and/or description of the action being approved:

This justification provides the rationale for contracting by other than full and open competition to award a sole-source Indefinite Delivery Indefinite Quantity (IDIQ) contract to Spirit AeroSystems (Spirit) for manufacturing of refractory composite coupons, and subcomponents, at the research and development (R&D) level. This would include Carbon/Carbon (C/C) and Ceramic Matrix Composites (CMC). NASA is also interested in polymer matrix composite (PMC) manufacturing of analogous structures to assist in refractory-composite R&D, testing of composite coupons, subcomponent, and constituent materials. Manufacturing of refractory composites is a critical aspect of NASA’s continuing research in both airframe and propulsion applications and can be used for acquiring mechanical test data, which is used for material selection, structural design, and failure analysis.

3. FAR 6.303-2(b)(3) – A description of the supplies or services required, to meet the

Agency’s needs (including the estimated value):

NASA Glenn Research Center/GRC has a requirement for manufacturing refractory composite coupons and subcomponents in combination with related capabilities, including subcomponent and large-scale automated fiber placement, production of a range of fiber architectures in multidirectional reinforcement configurations, fabrication of large composite structure subcomponents in an unclassified and classified environment, and manufacturing capable of density control and functionally graded matrices. Manufacturing of refractory composites is a critical aspect of NASA’s continuing research in both airframe and propulsion applications and are required for mechanical testing used for material selection, structural design, and failure analysis.

The period of performance is 5 years, with a maximum potential value of $15,000,000.

4. FAR 6.303-2(b)(4) – An identification of the statutory authority permitting other than full and open competition:

The statutory authority permitting other than full and open competition is 10 U.S.C. 3204(a)

(1) as implemented by FAR 6.302-1 Only one responsible source and no other supplies or services will satisfy agency requirements.

5. FAR 6.303-2(b)(5) – A demonstration that the proposed contractor’s unique qualifications or the nature of the acquisition requires use of the authority cited:

The rationale supporting the use of 10 U.S.C. 3204(a) (1) is that there is only one responsible source and no other supplies or services will satisfy agency requirements, as described below.

This statement of work would supply manufacturing of composite coupons and subcomponents at the research and development (R&D) level, which are required for mechanical tests within multiple, ongoing NASA projects, using the skills and methods found at Spirit. Composite material would include Carbon/Carbon (C/C), Ceramic Matrix Composites (CMC), and polymer matrix composite (PMC) manufacturing of analogous structures to assist in refractory-composite R&D, testing of composite coupons, subcomponent, and constituent materials.

Spirit is the only facility capable of meeting the diverse scope of material fabrication to be used for mechanical testing at elevated temperature environments, as explained below.

NASA has a requirement for the automated fiber placement as well as the ability to produce a range of fiber architectures in multidirectional reinforcement configurations of large-scale subcomponents for hypersonic vehicles. There is also a need for the ability to fabricate these composite materials in an unclassified and classified environment using processes that are scalable to production volumes. The refractory composite manufacturing should be capable of density control and creating functionally graded matrices in C/C and CMC structures.

In addition to automated fiber placement, NASA is seeking flexible composite preforming capabilities to enable the manufacture of a range of structure applications and geometries.

These abilities include (1) multiple weaving and braiding approaches (3D and 4D orthogonal, 3D angle interlock, 2D, 3D and triaxial braiding, and 3D polar weaving), (2) weaving bifurcated preforms and preforms that enable joined composite structures such as Pi joints,

(3) multiple fiber types and fiber materials to produce preforms including carbon, quartz, and SiC fibers, and (4) custom fiber configurations through stretch breaking.

The minimum requirements above for the procurement cannot be supplied by any other contractor, as explained in sections 8 and 10 below. The specimens fabricated will be used for: coupon machining, non-destructive evaluation, ASTM standard mechanical tests, non-standard tests as defined by NASA, environmental conditioning/testing, data reduction, statistical analysis, development of and access to existing material databases, composite manufacturing documentation, and raw material specifications.

6. FAR 6.303-2(b)(6) – A description of the efforts made to ensure that offers are solicited from as many potential sources as practicable, including whether a notice was or will be publicized as required by Subpart 5.2 and, if not, which exception under 5.202 applies:

A notice to the Government Point of Entry (GPE) website (Sam.gov) was published on March 14, 2024, in accordance with FAR Subpart 5.2. This posting informed potential sources of NASA’s intent to award this sole-source contract to Spirit. The results of this synopsis are summarized in Section 10 below.

7. FAR 6.303-2(b)(7) – A determination by the contracting officer that the anticipated cost to the Government will be fair and reasonable:

The Contracting Officer’s signature on this document indicates that the Contracting Officer has determined that the anticipated cost to the government will be fair and reasonable. The Contractor shall be required to submit a proposal to be evaluated and negotiated by the Government. Prior to execution of the contractual instrument, a proposal analysis will be performed. The proposal analysis will ensure that the final agreed-to price for the contract action is fair and reasonable.

The guidance and techniques specified at FAR 15.404 and NFS 1815.404 will be followed during the proposal evaluation. If appropriate, price analysis and technical analysis per FAR 15.404-1(b) and (e), and NFS 1815.404-1(e) will be performed to determine and negotiate a fair and reasonable price. If price analysis is not appropriate, then cost analysis and technical analysis, per FAR 15.404-1(c) and (e), and NFS 1815.404-1(e) will be performed to determine and negotiate a fair and reasonable price.

8. FAR 6.303-2(b)(8) – Description of the market research conducted, and the results, or a statement of the reasons market research was not conducted:

A market research study performed in 2024 found that Spirit offers unique capability not found elsewhere in the industry for the design, fabrication, production, volume manufacturing of large-scale, complex, advanced composite aerostructures, which form the foundation of Spirit’s extensive composite capabilities for hypersonic flight.

A search on Spirit’s website yielded an article discussing the National Defense Prototype Center (NDPC), a joint collaboration between Wichita State University’s National Institute for Aviation Research and Spirit, which provides a secure space for high temperature materials testing, development, prototyping, and industrialization. The NDPC encompasses more than 125,000 square feet of manufacturing and lab space with processing and characterization capabilities, including high temperature testing, furnaces for fabricating and processing materials, multi-method non-destructive inspection, robotic automated fiber placement technology and a large autoclave [see link (1)]. Another article highlights the quantity and capabilities for technology development and automation with Spirit possessing more than 30 autoclaves, including several of the largest autoclaves in the world for production of refractory composite materials at scalable volumes and 15 automated fiber placement machines [see link (2)]. Through collaboration with NASA subject matter experts, Spirit can meet high-capacity production demands and perform all phases of product powder systems, metrology and characterization, machine tooling, large-scale metal systems, and robotics and automation. The Manufacturing Demonstration Facility, in partnership with industry, develops and demonstrates the latest advancements in new manufacturing systems, materials and processes. [see links (6) & (7)].

On Spirit’s website, a certification by Orion Registrar is archived at the Biddeford, Maine location for the quality management system of FMI applicable to design, manufacture, and testing of advanced composites, high temperature insulation, and as a provider of material solutions for challenging applications [see link (8)]. These certifications support NASA’s requirements to produce a range of fiber architectures in multidirectional reinforcement configurations of large-scale subcomponents for hypersonic vehicles, including multiple weaving, preform, and custom fiber types of composite materials.

All of the capabilities and certifications discussed above, under the Spirit brand, provides NASA with an option not seen anywhere else in industry with such expertise and ability within one, original organization structure.

Links:

(1) https://www.spiritaero.com/pages/release/spirit-aerosystems-opens-national-defense-prototype-center/

(2) https://www.spiritaero.com/pages/article/spirit-solidifies-position-as-worlds-largest-user-of-afp-technology/

(3) https://www.mainebiz.biz/article/maine-manufacturer-of-high-temp-materials-will-expand-driven-by-defense-space-industries

(4) https://www.spiritaero.com/pages/release/recent-acquisition-of-fmi-expands-defense-capabilities/

(5) https://www.teamtextiles.com/news

(6) https://www.flightglobal.com/fixed-wing/spirit-aerosystems-seeks-to-develop-new-materials-for-hypersonic-flight/154477.article

(7) https://www.spiritaero.com/pages/release/spirit-aerosystems-oak-ridge-national-laboratory-sign-memorandum-of-understanding-to-create-strategic-partnership/ https://www.aerospacemanufacturinganddesign.com/news/spirit-aerosystems-ornl-partner-hypersonics/

(8) https://www.spiritaero.com/company/certifications/

The NASA technical team has had discussions confirming, or have knowledge of, subject matter experts in both government and industry, who regularly engage with and source requirements with Spirit as the only entity in the country that can perform the desired work.

9. FAR 6.303-2(b)(9) – Any other facts supporting the use of other than full and open competition:

None

10. FAR 6.303-2(b)(10) – A listing of the sources, if any, that expressed an interest in writing in the acquisition:

A notice of NASA’s intent to award this sole-source action was synopsized on the GPE website (Sam.gov) per FAR Subpart 5.2 (See Section 6 above). The capability requirements were posted on March 14, 2024, and closed on March 29, 2024.

Only one response was received on March 14, 2024, stating that they were able to do the required work. It was determined by NASA that the entity was not capable to complete the work due to the reasons listed below:

- No mention of the ability to perform automated fiber placement in Nv.

- No mention of manufacturing capabilities.

- No mention of the ability to perform work in a classified in their capability statement.

- The material mentioned is used for nose tip application, but NASA is specifically interested in propulsion and airframe applications. NASA also requires multiple fiber architecture options to support the propulsion and airframe application needs from a material design perspective. These complex structures need to be built as a preform, not machined from a block.

- The blocks of material are not scalable to the airframe and propulsion applications, specifically the large-scale parts that would need to be performed, instead of machined.

11. FAR 6.303-2(b)(11) – A statement of actions, if any, the agency may take to remove or overcome any barriers to competition before any subsequent acquisition for the supplies or services required:

The market for coupon-level materials testing is very large, and there are many vendors who do their own version of manufacturing. However, the manufacturing from those vendors do not meet the specific Agency requirements in Section 5. Barriers to competition have been created as a result of entities in this industry becoming individual experts in generating their own manufacturing requirements based on their business needs, rather than based on the needs of other businesses and agencies around the country. By publicizing the information generated from the manufacturing completed by Spirit, NASA can help to remove barriers to competition for any future procurement. There is also collaboration between NASA and Spirit, aimed at reducing the cost and increasing the production rate of composite structures made in the United States.

Fabrication of Composite Coupons, Subcomponent, and Constituent Materials

JUSTIFICATION FOR OTHER THAN FULL AND OPEN COMPETITION

SIGNATURE PAGE

I certify that the facts presented in this justification are accurate and complete.

Andrew Brune Technical Representative

I hereby certify that the above justification is complete and accurate to the best of my knowledge and belief.

Ashlee Shaw Contracting Officer

CONCURRENCE:

Kurt Straub Procurement Officer

APPROVED:

Leahmarie Koury Competition Advocate Glenn Research Center

ANDREW

BRUNE

Digitally signed by

ANDREW BRUNE

Date: 2024.04.11 10:54:24 -04'00'

Ashlee Shaw Digitally signed by Ashlee Shaw Date: 2024.04.11 11:02 05 -04'00'

Kurt Straub Digitally signed by Kurt Straub Date: 2024.04.16 21:30:48 -04'00'

LEAHMARIE

KOURY

Digitally signed by

LEAHMAR E KOURY

Date: 2024.04.19 11 36:31 -04'00'