FA8650-21-S-5001_Atch 5_Statement of Objectives - SOO.pdf

Statement of Objectives

Manufacturing Research and Technology Development

1. Introduction

Air Force Research Laboratory, Materials & Manufacturing Directorate (AFRL/RX) is seeking manufacturing technology research and development focused on strengthening defense manufacturing capabilities through the discovery of new manufacturing capabilities and efficiencies, and transitioning capability to the factory or depot floor. AFRL/RX is soliciting white papers and potentially full technical and cost proposals under this announcement to support the needs of its manufacturing and technology mission. Descriptors of manufacturing technology interests are presented below in the context of manufacturing research and technology development approaches and their applicability to the Air Force high impact technology domains.

2. Manufacturing Research and Technology Development Approach

The Air Force Manufacturing and Industrial Technologies Division (AFRL/RXM) is looking to apply advanced manufacturing technologies to systems in several technology domains: Advanced Concepts

(e.g. programs of record, existing AF systems), Attritable and Low Cost Systems, Networked C3 Systems, Hypersonic Strike and Emerging Technologies. In addition, AFRL/RXM intends to invest in manufacturing risk reduction opportunities associated with AFRL’s Transformational Capabilities programs, including

Vanguard programs such as Skyborg and Golden Horde.

2.1. Advanced Manufacturing Technologies

Agile processes are the key to making aerospace manufacturing and sustainment both responsive and affordable. Digital processes are inherently more agile, therefore enabling the accelerated availability and reduced cost of high-value technology to the warfighter. RXM’s new strategy focuses on delivering this digital infrastructure as a means to strengthen the industrial base, facilitate digital engineering, manufacturing and sustainment, and enhance efficiency and security. The following advanced manufacturing technologies can be applied to most or all high impact technology domains.

2.1.1. Future Factory

The objective of advancing future factory technology is to increase agility and responsiveness in aerospace manufacturing and sustainment through improved human-machine-technology teaming. Focus areas for the division are highlighted below.

2.1.1.1. Process Monitoring and Control

The Air Force is interested in the ability to monitor and control critical manufacturing processes for current platforms in production, as well as for understanding emerging processes in development. Data emerging from process monitoring techniques is valuable for decreasing processing variability, informing qualification, adding to the digital thread/twin and validating materials and process models. The Air Force is interested in the development and demonstration of advanced in situ sensors and other innovative methods to collect data and inform real-time decisions such as

FA8650-21-S-5001 Attachment 5 process parameter adjustment to ensure the product meets requirements. Advanced data analysis and statistical methods are of interest as well as the application of machine learning and artificial intelligence to the process monitoring and control environment.

2.1.1.2. Non-Destructive Evaluation/Inspection

Non-destructive evaluation (NDE) and inspection (NDI) technologies are used to ensure component quality specifications are met, structural and non-structural components and elements meet functional and operational requirements, and provide confidence to the user that fielded components will function as-designed.

NDE and NDI tools and capabilities are desired for structural and propulsion system and sub-system evaluations. NDE and NDI technologies of interest include hand held/operated systems as well as automated inspection technologies. The Air Force is interested in the development, demonstration and validation of these technologies using such tools as Probability of Detection (POD) methods and model assisted POD for structural and propulsion components, as well as determination of substructures

(i.e. microstructures or macrostructures for metals and fiber orientation for composite structures). Metrology includes the simulated and experimental measurement of system components including but not limited to dimensional measurements and geometric conformance characteristics of manufactured features, and the comparison and integration of component Computer Aided Design (CAD) with measured features and geometries for archival and subsequent analyses (e.g. as-manufactured assembly performance modeling, etc.). Additionally, the Air Force is interested in data analysis capabilities that autonomously and rapidly evaluate metrology and/or NDE/NDI collected data for damage or defect detection without the need of trained NDE or NDI personnel.

2.1.1.3. Virtual, Augmented and Mixed Reality for Manufacturing and Sustainment

Although many years in the making, Virtual/Augmented/Mixed (VAM) reality technologies are emerging, and will have enormous potential impact on manufacturing and service industries. The Air Force seeks to leverage VAM reality technologies to revolutionize aircraft maintenance across flight line maintenance, heavy maintenance (depot) and supply chain functions necessary for manufacturing or maintaining AF Systems. The Air Force seeks to utilize VAM to enhance maintainer proficiency, augment maintainer capability, and provide reliable data capture and visualization for actions such as maintenance and repair. For an enterprise-wide implementation of VAM technologies to aircraft maintenance, four areas of specific interest are:

1) Content Development defined as the computer generated visualizations for use in a VAM device independent of digital models of legacy aircraft systems;

2) Content Approval and Management solutions for vetting and managing VAM content;

3) Open Modular Enterprise Solutions that meet each use case and are deemed safest for that application; and

4) VAM Business Case for each use case considering first time quality and process throughput.

2.1.1.4. Advanced Robotics and Automation

The Air Force is seeking to develop and demonstrate advanced robotics and automation capabilities in manufacturing and sustainment environments such as:

1) Advanced automation applications that create highly flexible and reconfigurable systems working in tandem with – or augmenting – the human workforce to perform complex high-precision tasks, such as: coating, de-coating, aerospace fabrication, assembly, disassembly, integration, inspection and test;

2) Factory command and control utilities for highly autonomous factory floor execution;

3) Fully instrumented “smart” processes and equipment integrated into an enterprise-wide network for real time process monitoring, self-correction, dynamic re-scheduling of resources and automated preventative maintenance scheduling; and

4) Flexible and reconfigurable factory infrastructure, including modular, reusable, semi-automated and reconfigurable tools, fixtures, jigs and processes that can be quickly reconfigured to accommodate differing production requirements.

2.1.2. Digital Enterprise

The digital enterprise initiative aims to drive digital transformation throughout the enterprise to affect all aspects of the lifecycle of a weapon system: from cost-performance design tools to technical data packages to digital twin. Focus areas are highlighted below.

2.1.2.1. Moving Manufacturing and Sustainment Left

Moving manufacturing and sustainment left is a disruptive philosophy to foster greater awareness of producibility, industrial base, manufacturing readiness, and maintainability issues earlier in – and throughout – the acquisition process.

Fundamental to driving producibility and sustainability impact analyses into systems engineering practice, we seek to provide an analytical, mathematical basis for expressing producibility and to articulate life cycle cost impacts of improved decision-making. Development and demonstration projects are needed to determine what data, models, and analyses are needed to effectively evaluate producibility or industrial base readiness as a part of critical systems engineering reviews. Heuristic capabilities are needed to predict producibility outcomes as the engineering process moves from conceptual to preliminary to detailed design. Additionally, research is needed to determine the most useful output format of such analyses (corresponding to each review or milestone), such as probability of defects, expected number and cost of engineering changes, or clearly illuminated cost and schedule impacts. Finally, the data needed to support these objectives for “moving manufacturing left” will require closer interaction between the AF and its partners/suppliers in Industry; thus, technologies which facilitate exchange of models and data between AF and Industry in support of preliminary design will be necessary. In support of a goal of providing advanced analysis capabilities to improve early systems engineering activity and reduce late engineering changes, current focus areas include:

1) Multidisciplinary tools and environments to evaluate producibility, industrial base responsiveness, and supportability during transition from preliminary to detailed design; clearly illuminated cost and schedule impacts for ongoing programs.

2) Artificial intelligence capabilities to predict producibility outcomes by extrapolation on sparse data, associated with conceptual and preliminary design choices and similarity-based reasoning.

3) Proven architectural concept(s) that facilitate exchange of models and data between AF and Industry in support of preliminary design, including multidisciplinary analysis and optimization.

2.1.2.2. Agile, Digital Supply

This capability is essential for rapid response to changing warfighter needs.

Responsiveness implies a supply base capacity for timely reaction; effective integration of this capacity implies it is composable and configurable, with transparent and complete information flows and well aligned objectives. Tomorrow’s supply base

– an increasingly complex and dynamic management environment for the AF and its prime contractors – is globally distributed, and networking capabilities must account for the complexities of integrating and operating across differing infrastructures, languages, and cultures. Classic management issues such as supplier discovery, capability matching, and information exchange are far more effective through the use of web-based tools and methods and advanced modeling techniques. Status of specific issues – or of entire sectors – can be provided real-time. Three critical sub-thrust investment areas to achieve a responsive, integrated supply base vision are:

1) Insight into Supply Base Status – The Air Force and its OEMs and sustainers can more effectively build and manage an agile supply chain by having dynamic access to information representing suppliers’ capability, capacity, and cost and quality history. Additionally, real-time asset visibility enables supply chains to react quickly and proactively to conditions affecting cost, quality and delivery.

Enterprise web 2.0 (social networking) capabilities could represent a paradigm shift in supply chain communications, providing a modern link from the field to the depot and from the OEM to its supply chain. Additionally, validated models for real time assessment of supply chain resiliency, including data flows and business rules extensible for Industrial Base analyses and supply chain management are sought.

2) Enterprise Integration refers to the technologies and methods for information and process integration, stressing secure and seamless information exchange and integration with suppliers and customers. Systems gain robustness through collaboration using instant contracts and public/private partnerships. A globally distributed supply base can form and operate more effectively based on standard exchange methods. Interest areas include cloud-based information technology services and concomitant business case data supporting massive efficiency savings; tools and architectures to reduce supply chain data exchange costs by 50%; and recommendations and use-case results for deployment of capabilities for secure supply transactions.

3) Business Analytics – Web-based capabilities providing dynamic status information and advanced networking capabilities for integrating a globally distributed network will create numerous opportunities to ask new questions about risks and impacts and to develop the supply chain as part of the product design. Sources can be certified to verify the integrity of systems provided. New tools and capabilities will be needed to address these opportunities, and advanced risk management tools and supply chain management processes that leverage those, as well as analytical capabilities for supply chain design to facilitate proactive AF engagement in support of priority warfighter effects (e.g.

low-cost, attritable systems, hypersonics etc.).

2.1.2.3. Digital Thread/Digital Twin for Acquisition and Sustainment

The formal definition for Digital Thread is located in the DAU Glossary of terms; in short, it refers to the Thread as a “framework” to organize data across the lifecycle into an authoritative source that supports decision-making. And that is its real value – providing a means to bring data from wherever it resides into the analytical space.

Merely organizing the data and making it more accessible creates enormous efficiencies.

The thread is a means of transforming the decision processes that dominate all acquisition and sustainment phases. Among its goals is a desire to rethink analytical steps to ensure they capitalize on the availability of ALL information. The capacity to integrate numerous models facilitates use of science and physics where rules of thumb have often been acceptable. It enables quantification of uncertainty for analytical steps and better estimations of cost and risk. Finally, the digital thread seeks to connect decision making across lifecycle phases, eventually closing the loop so that future systems have insight into the decades of lessons learned from past programs.

AFRL’s Digital Thread efforts have been at the forefront of the wider Digital

Engineering movement, providing direct technical insight and vision for the working groups that penned the Digital Engineering Strategy. Included below are several interest areas that will be contemplated in the next few years to validate digital thread/digital engineering tools and architectures.

1) Advanced data curation architecture for lowered uncertainty in acquisition decisions

2) Digital thread artifacts and workflows for engineering support analysis in acquisition (e.g. life cycle sustainment plan, DMSMS/obsolescence management, supply planning, etc.)

3) Data models and engineering workflows to support sustainment analyses (e.g.

supply planning, sustaining engineering requests, tail-number-specific maintenance intervals, etc.)

4) Roadmap of complementary activities to coordinate digital transformation activity across DoD services, NNMI institutes, NASA, and DoE.

2.1.2.4. Cybersecurity for Advanced Manufacturing

AFRL/RX’s cybersecurity posture is largely based on collaborating with multiple R&D institutes and related activities. There are specific technology development efforts envisioned.

1) Within the factory: advancing machine monitoring for connectivity and threats;

innovating or furthering specific controls for risk identification and mitigation;

streamlining specific manufacturing processes with actionable intelligence and intrusion alerts; integrating multiple levels of security screening to qualify parts or components; and furthering technical innovations to develop the next-generation of secure, open control systems and interfaces.

2) Within the supply chain: verification and validation of authenticity of materials and components against counterfeit and off-specification materials; physical tracking and anti-tampering strategies for components and inventories throughout the supply chain network; secure and efficient communication between suppliers and customers at all levels of the supply chain; protecting data and IP from exposure and theft; integration of a multitude of systems that vary in age, sophistication, and architecture; and, analysis and modeling of the widely diverse systems, equipment, and processes across the supply chain network.

2.1.3. Additive Manufacturing

The objective of advancing Additive Manufacturing technology is to accelerate manufacturing for hard-to-source legacy parts and enable new design and manufacturing paradigms for next-generation weapon systems capabilities.

2.2. Technology Domains

To amplify impact, advanced manufacturing technologies are focused on five technology domains that are high priority for the Air Force. These technology domains are:

Advanced Concepts

Attritable and Low-Cost Systems

Networked C3 (Command, Control and Communication) Systems

Hypersonic Strike

Emerging Technologies

Each of these Technology Domains are further described in the following paragraphs.

2.2.1. Advanced Concepts

This technology domain directly supports programs of record and classified S&T development programs in achieving their missions. The manufacturing goals include reducing cost and cycle time for performance and risk benefits in both acquisition and sustainment, and enabling an increased capability, with a minimum Return on Investment (ROI) of 10:1. Current focus areas within this domain are summarized below.

2.2.1.1. Metals Processing & Fabrication

Metallic components comprise a significant proportion of the materiel procured by the Air Force. For example, the F-35 is 65% metal by weight. Continued development is required to reduce the cost and weight of metallic components while increasing the availability and performance of systems utilized by the Air Force. Areas of interest encompass metals processing and fabrication technologies that meet these goals for both man-rated and unmanned systems, and performance-driven engine applications powering current aircraft. Examples of fabrication processes include near net shape casting, forging, rolling, drawing, joining/welding, and low cost tooling. For high performance turbine engines, the Air Force is interested in innovative core and casting technologies, as well as hybrid disk and integrally bladed rotor manufacturing and sustainment improvements. The Air Force is also interested in processing technologies to control microstructure and create location-specific properties, and novel nondestructive evaluation methods to support advanced manufacturing and sustainment activity.

2.2.1.2. Thermal Barrier and Environmental Barrier Coating Application

Thermal barrier and environmental barrier coatings are applied to critical components where environmental conditions may exceed parent material capabilities. Application of these coatings allows for higher operating temperatures and extends component life. However, significant process shortfalls exist and new manufacturing technology is required. The objectives of manufacturing technology development in the area of thermal barrier coatings (TBCs) and environmental barrier coatings (EBCs) are to:

1) Eliminate processing as a constraint in product performance;

2) Reduce processing variability/improve process robustness in not only the TBC or

EBC, but also the associated bond coat; and

3) Reduce cost/cycle time in coating processing

Specific technologies of interest would include in-process control, inspection/non-destructive evaluation, modeling and simulation, automation, masking, surface preparation techniques, integration of data across the product lifecycle and maturing novel processes for TBC and EBC application. The Air Force is interested in reducing the variability of bond coats, and improving quality using process control techniques and quantifying quality with nondestructive evaluation. In addition, understanding of manufacturing variability and its impact on service life through digital thread and integrated computational materials science and engineering offers potential enabling component life improvements. The use of artificial intelligence or machine learning techniques to analyze process and performance data to direct new procedures or improved coating is also of interest.

2.2.1.3. Organic Matrix Composite Processing & Fabrication

The Air Force is interested in utilizing organic matrix composites to improve system performance with lighter-weight and higher-temperature structural components; to lower cost with predictable, optimized and agile manufacturing processes for components; and more sustainability from rapid insertion of robust materials with better as-manufactured performance baselines. The Air Force is interested in the processing of matrix materials including, but not limited to, epoxies, cyanate esters, bismaleimides, thermoplastics, polyimides and preceramic polymers. Understanding composite component variability over a range of resin materials, fibers and fabrics are also of interest. Innovations in processing including fiber placement, lay-up and consolidation, advanced and affordable tooling, bonding, adhesives, coatings, machining and process modeling are of interest.

Areas of strategic interest for the Air Force for large unitized structures include techniques to enable accurate composite part geometry for ease of assembly and defect-free components for structural integrity. Innovative methods for consolidation of composites materials (debulking, bagging and curing) are strategically important to enable cost and cycle time reductions along with improved quality. Composite bonding and co-curing methods are also of interest. Integrated computational materials science and engineering is of interest to significantly reduce or eliminate process iterations on high-value structures. The Air Force is interested in modeling, data management and processing capabilities that capture, disseminate, analyze and process data to enable more efficient manufacturing, assembly and maintenance methods for Air Force structural systems. The Air Force is interested in advanced, automated non-destructive inspection and data processing techniques to enable real-time decisions on structures as they are processed and to begin to populate the airframe digital twin.

2.2.1.4. EO/IR Sensors & Materials

As surveillance and tactical missions become more vital, there is a need to improve the performance of Infrared (IR) sensor systems and materials to enhance mission effectiveness while reducing costs. This requires current and next generation IR sensors with improved resolution, capability, functionality, and performance. In addition, there is a need for large planar and conformal IR windows that will increase the sensor field of regard, ease aircraft integration, and provide adequate environmental protection while maintaining performance requirements. The Air

Force’s objectives include increasing manufacturability and affordability for current and next generation IR sensors and materials. The focus should be on reducing cycle time, touch labor, and ultimately reducing the cost while increasing the size and/or capability of IR sensors and window materials. The IR sensors include, but are not limited to, Focal Plane Arrays (FPAs) and their components (integrated dewar coolers

(IDCs), IR detectors, Read Out Integrated Circuits (ROICs), and Infrared Search-and-

Track (IRST) systems). IR window materials include, but are not limited to, single crystalline and polycrystalline materials.

2.2.1.5. RF Systems & Materials

The Air Force must to be able to operate effectively in anti-access, area-denial environments as well as be able to disseminate “real-time” intelligence, surveillance, and reconnaissance data. This requires current and next generation ground, air, and space platforms to have Radio Frequency (RF) systems with improved bandwidth, capability, functionality, and performance. In addition, these systems need to have a smaller footprint and reduced weight, which forces the design to be highly integrated.

The higher level of integration is driving the manufacturing tolerances to decrease, as well as pushing the part-to-part variability to be tighter. In addition, the size and performance specifications for these systems drive the array architecture to be very difficult and expensive to manufacture and test. The Air Force objective is to increase the manufacturability, producibility, and reliability for current and next generation RF systems, including sensors and materials. The focus is on reducing cycle time, part count, touch labor, and ultimately reducing the cost of RF components and materials.

An area of emphasis is increased manufacturing readiness level and decreased transition and implementation risk. The RF applications include radar, electronic warfare, and communication systems. The materials/components include, but are not limited to, radomes, apertures, transmit/receive electronics, interconnects, time delay units, heat exchangers, power supplies, and receivers/exciters.

2.2.1.6. Sustainment

The Air Force Research Laboratory’s (AFRL) Sustainment Science & Technology (S&T) vision is to lead, discover, develop and transition technology solutions to ensure current and future fleets are safe, available and affordable. To support this vision, ManTech identifies and integrates manufacturing and inspection technologies for sustainment applications to reduce depot flow days, compress supply chain wait times, and manage supply chain risk. ManTech is interested in technology solutions to enhance the safety, availability and affordability of the legacy fleet. Success will depend on identifying specific, cost-effective sustainment application areas, and following through with transition efforts. Sustainment areas of interest include using robotics, automation and augmented/virtual reality to inform and document maintenance and inspection operations. Secure and portable systems to inspect and document aircraft conditions are key to improving depot efficiencies. Robotics and automation may be utilized within the sustainment environment for ergonomically challenging inspection and maintenance operations. Increasingly, robots need to work collaboratively with humans, be capable of repurposing (smart interchangeable end effectors), and have advanced sensing, metrology and perception capabilities.

2.2.1.7. Batteries and Energy Storage Technology

The Air Force is interested in novel approaches to the manufacture and sustainment of high-energy and high-power density energy storage to enable advanced warfighter, aviation, and mission support concepts. The lifecycle and performance of next-generation battery technologies is largely driven by manufacturing considerations from materials processing to cell and battery assembly. Areas of focus include but are not limited to manufacture and processing of high energy active materials, electrodes, solid state electrolytes and cells, and novel cell architectures. Additionally, the combination of advanced batteries with other energy storage and generation modalities including capacitors, fuel cells, and aircraft generators into hybrid power systems is desired to drive advances in aircraft mission capability. These systems must be capable of intelligently drawing upon the different energy storage subunits on demand with maximum efficiency to maximize overall system energy and power density. In support of battery sustainment efforts, priorities include leveraging automation and robotics to improve battery performance and lifetime, and drive down the cost of pack manufacture. The Air Force is interested in methods capable of predicting and maximizing battery lifetime performance through the integration of advanced characterization and monitoring techniques with artificial intelligence and machine learning into novel battery management systems. Finally, the automated assembly of battery packs in a low-volume/high-variability environment is necessary to reduce the high degree of touch labor traditionally involved in manufacture of aircraft batteries and drive down pack costs.

2.2.2. Attritable and Low-Cost Systems

This technology domain will aim to automate complex fabrication and assembly to reduce variability and touch labor, adapt non-aerospace materials, devices and processes for aerospace application, and manage comprehensive technical data packages to distribute manufacturing across multiple suppliers. Ultimate objectives include: enabling new CONOPS based on human-machine teaming and squads of autonomous aircraft with mission-specific configurations; enabling space systems with reduced life requirements for low earth orbit operations; and delivering low-cost platforms with rapid manufacturing response and technical refresh capability with no long-term sustainment tail. Current focus areas within this domain are summarized below.

2.2.2.1. Propulsion for Low-Cost Attritable Systems

The Air Force is interested in nascent low cost manufacturing technologies to enable game changing reductions in the life cycle cost of small/medium sized engines for unmanned platforms (200 – 3000 lbf thrust) and potentially for large manned engines

(> 3,000 lbf thrust). The limited-life requirements of these small engines requires process development for new and/or legacy materials optimized for this high-performance and short-endurance mission space. Examples of fabrication processes include near net shape casting, forging, rolling, drawing, joining/welding and low cost tooling. Other examples include Near Net Shape (NNS) Hot Isostatic Pressing (HIP) technologies, low cost tooling for NNS HIP, and low cost castings for complex turbine engine components. The Air Force is also interested in affordable machining technologies; in particular, advancements in low cost machining of superalloys to decrease cutting tool failure and improve yield, as well as high speed machining and techniques to reduce the variability of machining. Other machining technologies of interest include cryogenic or electro-chemical machining of aerospace materials.

Underlying all the low cost technology areas is the ability to perform trade space analysis and inform any cost vs. performance compromises.

2.2.2.2. Low-Cost Attritable Aerostructures

For low cost attritable structures, the Air Force is interested in exploring nontraditional (with respect to aerospace) composite and potentially metallic manufacturing techniques and materials for limited life structures and components, which may include affordable thermoplastics and other novel or nontraditional resins and processes. Low cost, short cycle time techniques such as out-of-autoclave processing, closed mold, and additive manufacturing for noncritical parts and tooling, is of interest, as well as methods to analyze cost and performance trades, especially as a function of production volume/surge. These nontraditional and novel materials and processes should have the capability to operate in a robust supply chain to enable fluctuations in demand. Modeling and analytical tools to expand the understanding of the material and manufacturing cost/performance/reliability trade space are of interest.

2.2.2.3. Sensors and Communications for Low-Cost Attritable Systems

The Air Force is interested in the application of advanced manufacturing technologies to reduce the cost, size, weight and power (C-SWaP) of sensor types which are complementary to attritable platforms. These technologies will enable “off-board” sensing and communications for disaggregated and autonomous operations in contested environments. Main sensor types of interest include, but are not limited to:

passive electro-optical / infrared (EO/IR); hyperspectral imaging (HSI); direct detection laser radar (LADAR); radio frequency (RF) signal characterization and direction finding

(DF); synthetic aperture radar (SAR); and ground moving target indicator (GMTI). In addition, there is interest in information protection technologies complementary to attritable sensors.

2.2.2.4. Low-Cost Space Systems

The Air Force is interested in the application of advanced manufacturing technologies to reduce C-SWaP and increase availability of current and next generation spacecraft bus and payload components and subsystems for limited life (1-5 years) operations in

Low Earth Orbit. Advanced manufacturing technologies such as automation and additive manufacturing to reduce touch labor, improve yield, reduce mass, minimize delivery time, and increase availability of low-cost space systems will be required.

Main areas of interest include, but are not limited to: spacecraft bus and payload components and subsystems; spacecraft bus and payload Assembly; Integration and

Test (AI&T); standards and modularity; non-traditional materials and components;

and reduced spacecraft materials and components qualification requirements.

Innovations for current production as well as new “clean sheet” concepts may be beneficial. A wide range of technologies may be explored, including, but not limited to: COTS/GOTS adaptations; open systems architecture; accelerated integration and test; modular, reconfigurable, scalable concepts; direct write; additive manufacturing;

and multi-functional structures.

2.2.3. Networked C3 (Command, Control and Communications) Systems

This technology domain is focused on enabling secure, robust, networked C3 in a contested environment and realize real-time, combat relevant information shared securely across the battlespace. The recent shift to digital beamforming and broadband apertures operating at millimeter wave frequencies, necessitates RF components get smaller by 3-10X, consume less power, and be heterogeneously integrated with the necessary transmit/receive components.

Instead of a large undertaking focusing on a traditional, monolithic array system, the desired operational capability is a multi-functional (Radar, EW, Comm), digitally-interconnected scalable phased arrays. Key objectives include: extension of RF performance into broad band millimeter-wave; improve manufacturing techniques for heterogeneous integration of RF and digital components; implement near junction heat extraction technologies; increase semiconductor operating temperatures; and increase operating voltage of RF and power switching components. Current focus areas within this domain are summarized below.

2.2.3.1. Wideband Multi-Function Digital Phased Arrays

The Air Force is interested in maturing the manufacturing of next generation multi-function digital phased array components to reduce touch labor, improve yield, increase availability, and reduce cost. Focus areas include, but are not limited to, radomes, apertures, transmit/receive electronics, interconnects, time delay units, heat exchangers, power supplies, receivers/exciters, and heterogeneous integration.

The use of element-level digital beamforming in phased-array antennas for communication enables multiple receive and transmit beams in multiple directions simultaneously, reducing node discovering time and improving network throughput.

2.2.3.2. Wide Bandgap Semiconductors

The Air Force is interested in maturing the manufacturing of next generation wide bandgap semiconductor materials and devices for high power RF phased array applications and next generation high voltage RF and power switching electronics.

Semiconductor materials include, but are not limited to, Gallium Nitride (GaN), Gallium Oxide (Ga2O3), and Silicon Carbide (SiC).

2.2.4. Hypersonic Strike

This technology domain aims to strengthen the industrial base capability to produce structural and functional organic and ceramic matrix composites, ceramic materials, metallic structures, and refractory coatings necessary for critical components for boost glide and air breathing vehicles and their associated propulsion. Ultimate objectives include enabling prosecution of high value, time critical targets from standoff ranges in heavily defended air spaces, and strengthening the US industrial base capability to reliably and repeatedly produce high temperature materials and systems in support of AF hypersonic mission objectives. Current focus areas within this domain are summarized below.

2.2.4.1. Ceramic and Ultra-High Temperature Composite Processing & Fabrication

High performance Ceramic, Ceramic Matrix Composite (CMC), and Ultra-High

Temperature Composite (UHTC) materials such as carbon/carbon (C/C), silicon-carbide/silicon-carbide (SiC/SiC), oxide/oxide (Ox/Ox), nano-composite optical ceramics (NCOC) and others, are needed for a variety of applications including propulsion systems, hypersonic structures, seals, hypersonic radomes, and windows/apertures. Current Air Force interest involves: manufacturing maturation of next-generation fiber-reinforced and monolithic structural and functional ceramic materials and components; lower cost and lower variability processing; and manufacturing process modeling. Focus areas include, but are not limited to:

advanced constituents - including manufacturing of silicon carbide and carbon fibers;

advanced fiber coatings; matrices; and other manufacturing process improvements that increase temperature capability, performance, manufacturability, or affordability beyond current limitations.

Understanding ceramic and CMC behavior in service environments begins with understanding the effects of environmental degradation at the constituent level during manufacturing. Consequently, exploring constituent-level variability resulting from a lack of robustness in existing manufacturing processes, and determining how that variability impacts the material performance of these extreme temperature components, are both high priority. Incorporation of Integrated Computational

Materials Science and Engineering (ICMSE) may be advantageous in order to couple processing, microstructure and performance via validated computational methods that accelerate materials and process development, transform engineering design optimization, and unify design and manufacturing. Low cost methods for machining and joining ceramics, CMCs, and C/C are also of interest. The goal is to reduce insertion risks, increase yield, lower costs, and decrease development and manufacturing cycle times for these materials in order to take full advantage of the performance gains they offer.

2.2.4.2. Process Monitoring & Nondestructive Evaluation/Inspection for

Fabrication of Hypersonic Materials

Due to the complexity of these material systems, geometries, and fabrication processes, current state-of-the-art equipment and techniques are limited in their ability to provide sufficient in-process monitoring information and to perform sufficient nondestructive inspection during and after component fabrication. The Air

Force is interested in the development, demonstration, and validation of process monitoring and nondestructive evaluation/inspection (NDE/NDI) techniques to monitor/assess key processing parameters and critical-to-quality parameters in geometrically complex high temperature material systems. Techniques of interest include those capable of providing in-situ (during a processing step), in-process

(between steps), and post-process (fabrication complete) information. Material systems of interest include, but are not limited to, ceramics, C/C, CMCs, and refractory and additively manufactured metals.

The Air Force is interested in monitoring or inspection techniques that require minimal intervention by trained technicians, and employ statistics-based data processing and analysis methods to efficiently and reliably translate raw data into material characterization information, defect indications, or part nonconformance with high confidence probability of detection (POD); model-assisted POD methods are also of interest. Another key interest is in unifying design with manufacturing, wherein results of in-situ, in-process and post-process inspections are captured digitally with necessary, software agnostic metadata for input to ICMSE tools – enabling integration of process/inspection data into upstream processes or future designs for improved manufacturability.

For in-situ techniques, primary interest is in providing real-time decision quality information on the status of the entire part undergoing processing often in harsh environments. Techniques to be employed between processing steps or when part fabrication is complete should be automated and capable of complex contour following and interrogation of: internal channels, tight radii, bonds, joints, and interfaces, with minimal required technician interaction.

2.2.4.3. Air-breathing hypersonic systems

The challenges of flight at speeds greater than Mach 5 require careful analysis and thoughtful solutions. Well-known material and design solutions do not necessarily work in a hypersonic heating and dynamic pressure environment. Not only is this problematic for vehicle structure, but for air-breathing propulsion as well. Current Air

Force interest involves manufacturing maturation and solutions for air-breathing hypersonic vehicle structure, propulsion and other necessary hardware required for hypersonic missions. Examples of structure focus include, but are not limited to, nosecone, interior support, skins, seals, control surfaces, as well as dissimilar materials joining and attachments. In the propulsion system focus areas are the inlet, isolator, combustor, nozzle, and other necessary propulsion support structure. Examples of other necessary hardware are flight controls, avionics, actuation, fuel systems, antennas, navigation, or similar non-structural hardware. Demonstration of alternative production methods moving from small demonstration quantities to larger production runs is of interest, as well as optimizing existing production methods -particularly for difficult to manufacture complex shapes, and reduction in part count.

Affordability, variability, cycle time reduction, and assessment of critical to quality parameters across these areas are each of high importance.

2.2.4.4. Air Launched Rocket Booster

Air Launched Rocket Boosters have been identified as a key cost and performance driver for hypersonic vehicles. Advances in booster manufacturing are sought in the areas of booster case, propellant, throat, nozzle, attachments, physical integration, assembly, or related areas towards improved producibility and scalability.

Development, refinement and implementation of automation in key processes should be considered. The goal is to reduce insertion risks, increase yield, increase reliability, lower costs, and decrease development and manufacturing cycle times for air launched rocket boosters.

2.2.4.5. High Temperature Electronics

The Air Force is interested in developing and maturing manufacturing processes for high temperature electronic components and semiconductors for hypersonic applications. Active and passive electronic components include, but are not limited to, capacitors, crystal oscillators, diodes, integrated circuits, resistors, memory, sensors, transistors and printed circuit boards. Semiconductor materials include, but are not limited to, Silicon (Si), Silicon Germanium (SiGe), Gallium Arsenide (GaAs), Gallium

Nitride (GaN), Silicon Carbide (SiC), Indium Phosphide (InP), and Gallium Oxide

(Ga2O3).

2.2.5. Emerging Technologies

In order to meet the anticipated future technology needs of the Air Force, AFRL/RXM has identified three areas for which manufacturing and industrial base risk reduction efforts will be needed for timely technology transition: directed energy weapons, biomanufacturing, and quantum technologies. These areas are described in more detail below.

2.2.5.1. Manufacturing for Quantum Technologies

The Air Force is interested in developing critical manufacturing technologies for quantum enabled chip scale atomic clocks and inertial sensors, and scaling up manufacturing processes /enabling technologies for integrated quantum photonics.

Other investment areas include but are not limited to manufacturing technologies related to quantum sensing, communication, networking, and computing.

2.2.5.2. Manufacturing for Directed Energy Weapons

AFRL/RXM intends to improve the manufacturing and industrial base for directed energy weapon (DEW) systems that will enable new CONOPS for Airbase Defense, Precision Strike, and Protection/Self-Protection using High Energy Lasers (HEL) and

High Power Microwaves (HPM) technology. An additional goal is to mitigate supply chain risks identified by the OSD Industrial Base Analysis and Sustainment (IBAS) and

Joint Defense Manufacturing Technology Panel (JDMTP) DE DoD ManTech roadmaps for HEL and HPM Weapon Systems as the demand for DEW systems increase across the DoD.

2.2.5.3. Biomanufacturing

AFRL/RXM is interested in exploiting synthetic biology to manufacture aerospace materials to enable a reliable, sustainable and agile supply chain while limiting logistics vulnerabilities. For example, biomanufacturing is expected to deliver sustainable and affordable complex new materials with enhanced physical and mechanical properties. Key factors to be consider are: optimizing pathways for maximum production yield, enhancing reproducibility and predictability of the synthetic pathway, and scaling up processes to commercial volumes.

2.3. AFRL Transformational Capabilities

Consistent with the Air Force Science & Technology 2030 Strategy, AFRL has committed to developing and delivering Transformational Capabilities in support of Air Force operational needs.

In order to accelerate the transition and adoption of these Transformational Capabilities, AFRL/RXM intends to assess and reduce the manufacturing risk associated with these efforts. AFRL/RXM is therefore interested in projects that would address manufacturing, supply chain, and industrial base issues associated with AFRL Transformational Capability efforts such as Vanguard and Seedlings for

Disruptive Capabilities programs.

3. Period of Performance

Each award will have an anticipated PoP to be between 12 to 40 months. This will include a technical PoP and an anticiapted 3 month draft/final reporting PoP.

4. Deliverables

To be determined per award. See list of CDRLs attached to BAA.

5. Security Requirements

5.1. Operations Security (OPSEC)

The contractor shall participate in all activities associated with the disciplines of the organization’s

Industrial Security, Information Security, Personnel Security, Operations Security (OPSEC), and

Antiterrorism programs, following appropriate measures in each program as required for this particular contract. Security measures are required to reduce program vulnerability from successful adversary collection, exploitation of critical information, and violations of export control requirements. The prime contractor shall ensure all subcontractors, if applicable, conform to these requirements as required by the prime contractor.

5.2. Program Protection Plan (PPP) Requirements

Any potential critical program information (CPI) generated as part of this effort will be reviewed to determine the need for a PPP or to be included as part of an existing PPP.