Intact Solutions, Inc.

Intact Solutions, Inc. is a for-profit small business located in Madison, Wisconsin, that specializes in advanced engineering simulation, design optimization, and additive manufacturing research. The company has established itself as a key federal contractor and grantee, providing sophisticated software tools and research solutions focused on thermal simulation, topology optimization, generative design, and complex manufacturing processes. Intact Solutions has secured significant federal funding from defense, scientific, and manufacturing-focused agencies, demonstrating expertise in cutting-edge technologies that support national innovation priorities in advanced manufacturing and digital transformation.

Through federal contract awards, Intact Solutions has provided research and development services primarily in the small business innovation research (SBIR) and small business technology transfer (STTR) programs. The company received a $1.89 million SBIR Phase II contract from the Defense Advanced Research Projects Agency (DARPA) awarded January 1, 2026, for the CommandIt project, which focuses on developing systematic methodologies and computational frameworks for constructing predictive manufacturing digital twins from heterogeneous data sources, with completion scheduled for December 31, 2028. Additionally, Intact Solutions was awarded a $1.79 million SBIR Phase II contract by DARPA (Research Development and Engineering Command) in July 2024 for generative design with pre-qualified additive manufacturing under NIST Topic 2020 NIST 02, extending through August 2026. The company also received a $150,000 firm fixed price purchase order from NASA's Shared Services Center under SBIR Phase I for developing a plug-and-play approach for topology optimization of thermal control systems, performed from July 2022 through January 2023. Furthermore, Intact Solutions secured a $149,987 STTR Phase I contract from NASA's Shared Services Center, also awarded July 25, 2022, for developing an application programming interface for the design, simulation, and optimization of tow-steered composites, with completion in August 2023. All contract awards carried small business set-aside designations, reflecting Intact Solutions' status as a qualified small business contractor.

Intact Solutions has secured multiple federal grant awards supporting advanced manufacturing research and software development. The company received a $106,500 Cooperative Agreement from the National Institute of Standards and Technology (NIST) under the Science, Technology, Business and/or Education Outreach program (CFDA 11.620), awarded August 1, 2025, to develop a thermal history simulation framework for multi-laser powder bed fusion additive manufacturing platforms, leveraging the company's proprietary Contact-Aware Path-Level (CAPL) discretization technology, with performance through January 31, 2026. The Department of Energy's Office of Science awarded Intact Solutions a $206,500 Project Grant under the Office of Science Financial Assistance Program (CFDA 81.049) on February 18, 2025, to support scalable deployment of the MFEM software framework for generative design and additive manufacturing applications, concluding November 17, 2025. NIST also awarded Intact Solutions a Cooperative Agreement beginning October 1, 2023, to develop new scan patterns and reduced-order models for predicting path-to-part scale thermally-induced properties in laser powder bed fusion additive manufacturing, with expected completion September 30, 2025. Additionally, Intact Solutions received a $252,805 Cooperative Agreement from NIST under the Measurement and Engineering Research and Standards program (CFDA 11.609) from September 1, 2021, through August 31, 2023, for contact-aware path level thermal simulation of powder bed fusion. The company also serves as a sub-awardee under the University of Wisconsin System as prime grantee, working on demonstrating scalable path-to-part thermal simulation for powder bed fusion processes, with collaboration from GE teams and Navy consultation, as documented in an award dated September 3, 2024.

Intact Solutions holds an Other Transaction (OT) Indefinite Delivery Vehicle (IDV) contract awarded by the Defense Advanced Research Projects Agency (DARPA) on July 2, 2025, valued at $499,887, without set-aside designation. This IDV contract focuses on the research project "Digital Twins for Resilient Mechanical Interfaces," leveraging Intact Solutions' expertise in advanced engineering simulation, design optimization, and additive manufacturing research to provide sophisticated software tools and research solutions. The OT IDV structure allows DARPA to issue task orders under this vehicle for research and development work related to digital twin technologies for mechanical interface resilience, positioning Intact Solutions to support DARPA's ongoing research objectives in advanced manufacturing and simulation technologies.