DON26BZ01-DV043 — DIRECT TO PHASE II: Highly Loaded Grain in 2.75" Form Factor
Award Maximum: $1,400,000 Period of Performance: 30 months (Base) + 12 months (Option) Phase Type: Direct to Phase II (DP2)
OBJECTIVE: Design, develop, and demonstrate a Highly Loaded Grain (HLG) technology in a 2.75 inch rocket motor to extend range in a tactically relevant form factor.
DESCRIPTION: The objective of this SBIR Direct to Phase II topic is to utilize HLG to increase the range available in a 2.75" rocket motor and advance the Technology Readiness Level (TRL) and Manufacturing Readiness Level (MRL) of HLG technology. HLG is a propellant technology that improves total impulse in a given volume, as well as provides capability for mission flexibility. The Mk66 is a low cost 2.75" rocket motor utilizing minimum smoke propellent and is in use with unguided rockets and the Advanced Precision Kill Weapon System (APKWS II) All Up Round (AUR). Increasing the range available at an affordable cost in a Mk66 motor case is needed to pace emerging threats.
Key Technology Guidelines:
Rocket motor case: 2.75" Mk 66 case
Grain design: HLG propulsion technology
Ballistics software: CLWire provided by the Naval Air Warfare Center Weapons Division (NAWCWD)
Risk posture: Low/moderate risk for non-HLG specific components
Total Impulse: Increase by 30%
Thrust Profile: Implement all-boost and boost/sustain thrust profile with performance guidelines provided by NAWCWD (Maximum Expected Operating Pressure (MEOP) and initial thrust dictated by legacy Mk 66 system)
Propellant: Objective: Min-Smoke, Threshold: Reduced Smoke
Materials: Maximize compatibility/usage of existing rocket motor materials (propellant oxidizers and binders, insulation, liners, etc.)
Environments: thermal (-65 °F to 160 °F) (-53.9 °C to 71.1 °C) and mechanical environments (shock/vibe) required to enter military usage.
Nozzle and igniter: medium risk with path towards tactical design
PHASE I: For a Direct to Phase II SBIR topic, the Government expects that the small business has accomplished Phase I-type feasibility work and can document within the proposal submission to indicate previous research and development work has been conducted to design, implement, and test HLG propulsion technology in a "Phase I-type" effort. This work would include ballistic design, motor fabrication, and static test results. The feasibility documentation MUST NOT be solely based on work performed under prior or ongoing SBIR/STTR effort.
PHASE II: Develop an initial concept design incorporating the following elements: ballistics, insulation, nozzle, and igniter. This design will be formally documented and presented in a Detailed Design Review (DDR) to evaluate compliance with the technical requirements established in coordination with the Government. Approval of the DDR and its associated exit criteria is a prerequisite for advancing motor fabrication. Upon acceptance, the awardee will initiate fabrication activities, which include detailed design finalization, component and cast tooling production, and propellant mix and casting.
Following fabrication, the as-manufactured motor will undergo an Item Under Test (IUT) evaluation, during which its performance and specifications will be assessed relative to the original design concept. This review will be submitted to the Government for validation and approval. Subsequently, the motor will be static fired, contingent upon mutual agreement between the Government and the awardee.
Upon completion, the awardee will submit a final report to Naval Aviation Warfare Center Weapons Division (NAWCWD). This report will document the prototype's design, fabrication process, and test results. It will also identify any low-maturity technology areas and introduce a plan to further develop these technologies during Phase III.
The Government will furnish the motor case, HLG materials, and technical support as requested by the awardee throughout the award process.
PHASE III DUAL USE APPLICATIONS: Utilizing Phase II results, refine and execute risk reduction and technology maturation efforts to develop the design to an overall high TRL, and integrate into a full system, progressing towards potential integration into an existing program of record.
Dual uses include development of high-rate minimum-smoke propellant and HLG development toward rotary-wing applications.
Potential commercial industry utilization include pace-based applications, such as satellite thrusters/solid propulsion systems.