DON26BZ01-DV040 — DIRECT TO PHASE II: Extended Range 10-inch Air Launched Rocket

Award Maximum: $1,400,000 Period of Performance: 30 months (Base) + 12 months (Option) Phase Type: Direct to Phase II (DP2)

OBJECTIVE: Implement Highly Loaded Grain (HLG) propulsion technology into an existing 10-inch diameter rocket motor to create a tactically relevant, extended range rocket motor.

DESCRIPTION: The U.S. Navy is pursuing enhancements to the performance, range, and tactical flexibility of existing 10-inch rocket motor systems. A key enabler of this objective is the maturation and application of HLG propulsion technology. HLG designs maximize total impulse within volume-constrained tactical solid propellant systems while enabling adaptable thrust-time profiles, including boost-sustain variants.

This Direct to Phase II SBIR topic seeks integration of HLG technology into an existing 10-inch diameter rocket motor, thereby increasing performance and advancing the Technology Readiness Level (TRL) and Manufacturing Readiness Level (MRL) of the HLG propulsion approach.

Key Technical Guidelines:

1. Rocket Motor Case: 10-inch diameter tactical casing with boat-tail geometry based on the High-speed Anti-Radiation Missile (HARM) aft-end structure

2. Grain Design: HLG-formulated geometry tailored for constrained volume and thrust shaping

3. Ballistics Software: CLWire ballistic simulation software provided by Naval Air Warfare Center Weapons Division (NAWCWD)

4. Risk Posture: Low to moderate for non-HLG-specific subsystems; medium risk for nozzle/igniter design

5. Performance Objective: Total impulse increase of approximately 30% over legacy baseline

6. Thrust Profile: Support both all-boost and boost/sustain regimes; comply with NAWCWD performance parameters including Maximum Expected Operating Pressure (MEOP) and thrust onset rates

7. Propellant Formulation: Aluminized solid propellant: Ammonium Perchlorate (AP) / Aluminum (Al) / Hydroxyl-Terminated Polybutadiene (HTPB) binder

8. Materials Compatibility: Maximize re-use of existing materials for insulation, liners, oxidizers, and binders

9. Environmental Qualification: Thermal: –65 °F to +160 °F (–53.9 °C to +71.1 °C); Structural: withstand shock and vibration in accordance with military deployment profiles

10. Nozzle & Igniter Development: Moderate risk with identified maturation path toward tactically viable configurations

PHASE I: For a Direct to Phase II topic, the Government expects that the small business would have accomplished the following in a Phase I-type effort and developed a concept for a workable prototype or design to address, at a minimum, the basic requirements of the stated objective above. The below actions would be required to satisfy the requirements of Phase I:

1. Ballistic Design: Evidence of preliminary or detailed grain geometry development, performance modeling (e.g., with CLWire or similar), and total impulse optimization.

2. Motor Fabrication: Documentation of hardware build efforts, including grain casting, case integration, and materials characterization relevant to the HLG configuration.

3. Static Test Results: Data from one or more static firings that validate thrust-time profiles, ignition performance, MEOP survivability, and total impulse enhancement attributed to the HLG propulsion technology.

4. Importantly, feasibility documentation must not rely solely on work conducted under prior or ongoing federally funded SBIR/STTR awards. Applicants are required to demonstrate that the proposed concept has been advanced through non-SBIR/STTR-funded efforts, indicating technical maturity sufficient for immediate Phase II execution.

PHASE II: Focus on developing, documenting, fabricating, and validating a tactical solid rocket motor that integrates HLG propulsion technology, in accordance with Government technical guidelines and performance objectives.

1. Initial Concept Design and Detailed Design Review (DDR)

• Develop an initial system design incorporating: (1) Ballistic modeling using CLWire (Government-furnished); (2) Thermal and structural insulation design; (3) Tactically relevant nozzle architecture; and (4) Igniter configuration suited for aluminized propellant initiation.

• Document the full design concept for review in a DDR to be assessed against Government-agreed technical requirements and performance metrics.

• Government acceptance of DDR exit criteria is required prior to initiating fabrication.

2. Fabrication and Assembly (following DDR approval)

• Finalize design details, generate component drawings, and fabricate tooling for both component and propellant casting.

• Perform propellant mixing and casting per specified aluminized solid formulation (AP/Al/HTPB), ensuring compatibility with insulation and liner materials.

• Utilize a Government-supplied flight weight motor case and HLG-specific materials, as requested and made available by the program office.

3. As-Manufactured Validation and Testing

• Conduct an Item Under Test (IUT) review to compare the as-built motor configuration with the as-designed concept.

• Present findings to the Government for validation and alignment with performance expectations.

• Upon concurrence, proceed to static fire testing of the motor in a controlled test environment.

PHASE III DUAL USE APPLICATIONS: Mature the Phase II rocket motor concept for higher fidelity static fire demonstrations. The developed rocket motors will incorporate flight representative subcomponents (e.g., nozzle, insulation, ignition system, etc.) while still optimizing the propulsion design to maximize system range. Demonstrate multiple static firings to assess the environmental robustness of the rocket motors and performance relative to the technical guidelines provided by the Government. A final report will be provided that documents the design and testing results, provides a Technology Readiness Level (TRL) assessment, and outlines a path to further mature the technology.

The developed propulsion technology with have application to space launch and space-based systems.