Multi-Material Propeller Prototype

This is not a Request for Proposal (RFP) and award of a contract will not be made as a result of this posting.  Naval Surface Warfare Center, Carderock Division (NSWCCD) is conducting market research for a new contract to design, develop manufacturing processes, and manufacture both model scale and full scale Multi-Material Propeller Prototypes.

Background:

The Multi-Material Propeller Prototype project is currently in execution by a multi-organizational team including the government, multiple design agent contractors, and an incumbent manufacturer.  The design team is closely integrated with the manufacturer and the prototype is being designed to be fabricated by the incumbent manufacturer using the incumbent manufacturer’s processes and materials. This RFI is in support of the Government’s anticipated requirement to manufacture additional full scale and model scale prototypes beyond the awarded scope at the incumbent manufacturer.

NSWCCD Requirements:

a. Complete manufacturing of a full scale Multi-Material Propeller Prototype Blade by April 2026 (assumed award in March 2025).

 i. In order to meet the Government’s schedule by avoiding prototype redesign, the Multi-Material Propeller Blade must be made from materials as specified in the Government’s prototype design (to be selected by the Government in early 2024).  Materials included in the prototype consist of out of autoclave intermediate modulus and standard modulus carbon fiber pre-pregs, super duplex stainless steel, versathane (SC86283-2121), urethanes with specified properties, and proprietary material patented by the incumbent manufacturer.

1. The incumbent manufacturer’s material is critical to the Multi-Material Propeller Prototype’s design.  Any substitution would require either the follow-on manufacturer to develop and validate a new material with identical properties, or a redesign of the prototype component to feature another material.

ii. Full scale blade will have section thickness in excess of 10 inches in some areas and consist of approximately 3,000 lbs of composite material per blade.

iii. The blade must be assembled in accordance with the Government’s design which will require machining of composites, urethanes, and stainless steel in one machining setup.

b. Complete model scale manufacturing of model scale Multi-Material Propeller Prototype rotors by April 2026 (assumed award in March 2025).

i. Model scale prototypes will be designed with the same materials as the full scale prototype

ii. Subject to same assembly/machining requirements as full scale unit

iii. Model scale prototype will be roughly 1/3 scale and finished rotor diameter is approximately 5 ft in diameter.

c. Prior to manufacturing, the offeror must demonstrate the capability to process the selected structural composite materials with sufficient quality that meets project objectives.

i. Material quality must be assessed by successfully meeting or exceeding the fatigue life demonstrated by the materials processed by the incumbent manufacturer at 1E8 cycles. 

d. Prior to manufacturing, the offeror must generate a manufacturing process, design, and procure tooling that meets the Government design’s intended assembly requirements and order of operations.

e. Prior to manufacturing, the offeror must demonstrate the ability to process and achieve the properties required for the urethanes and patented materials.

NSWCCD Questions:

1. Does the offeror have experience in executing similar efforts?
2. Does the potential offeror have the capability to execute the required scope within the required timeline subject to the constraints and order of operations described above?
3. Does the potential offeror have access to and capability to process pre-preg carbon fiber, various urethanes including versathane (SC86283-2121), and the incumbent manufacturer’s proprietary patented material?
4. The Government does not have the current prototype design drawings available as the prototype design is going to be selected by the Government in early 2024. Asides from that, are there any other barriers that would cause hardship in proposing for this effort?

Response to NSWCCD requirements shall not to exceed 15 pages. Interested offerors shall describe their capabilities to meet the requirements and inform the Government if any of the requirements create a barrier that would not allow for the offeror to propose. The response shall also provide the point of contact for the Offeror and its business size.

NSWCCD intends to fulfill this requirement via a Cost-Plus-Fixed-Fee (CPFF) completion contract with an anticipated award date of March 2025.