DAF SBIR DAF27BZ01-DV011: Agile Wire Harness Manipulation and Installation for Unmanned Aerial Systems

Quick Answer

DAF27BZ01-DV011 is a Department of the Air Force SBIR Direct to Phase II topic in DoW SBIR 2027 BAA Release 1 for a modular, single-arm robotic workcell that autonomously routes, aligns, inserts, and verifies flexible wire harnesses and connectors inside unmanned aerial systems and munitions. Awards are up to $2,000,000 over up to 24 months, closing November 25, 2026 at 12:00 p.m. ET.

The bar is specific: insertion accuracy of 0.5 mm or better, at least 2x cycle time improvement, at least 50 percent fewer skilled labor hours per unit, retasking to a new harness family in under 8 hours, and a machine-readable digital thread for every step. Applicants need a TRL 4 baseline.

Topic at a Glance

• Topic number: DAF27BZ01-DV011
• Title: Agile Wire Harness Manipulation and Installation for Unmanned Aerial Systems
• Component: Department of the Air Force
• Solicitation: DoW SBIR 2027 BAA, Release 1
• Program and phase: SBIR Direct to Phase II
• Award ceiling: $2,000,000
• Period of performance: 24 months
• Technical volume limit: 35 pages or slides
• Projected CMMC level: Level 2 (Self)
• Export control: Not marked as ITAR restricted on DSIP
• Focus areas: Advanced Manufacturing; Hypersonics; Space Technology; Trusted AI and Autonomy
• Keywords: robotic wire routing, deformable material manipulation, autonomous harness installation, single-arm workcell, blind-mate connector insertion, tactile feedback, computer vision alignment
• Pre-release: October 7, 2026
• Opens: October 28, 2026
• Closes: November 25, 2026 at 12:00 p.m. ET
• Submission portal: DSIP at dodsbirsttr.mil

What the Air Force Is Looking For

Wire harness routing and connector insertion are the largest automation gap in UAS and munitions production. Flexible cabling deforms unpredictably, so hard-tooled robotics fail, and manual work limits surge capacity and introduces latent defects such as partially seated connectors and overstressed wires.

The Air Force wants a COTS collaborative arm on a reconfigurable base, with interchangeable end-effectors, local real-time compute, and a vision, tactile, and force-torque sensor stack. It must combine offline CAD-driven path planning with real-time adaptive control and human-like search and settle behavior for blind-mate insertions. The primary use case is wiring for the Franklin Affordable Mass Missile (FAMM) and Coyote missile families, with demonstrations at defense prime manufacturing sites.

Minimum deliverables

• One integrated single-arm robotic workcell with the full multi-modal sensor stack.
• Unencumbered delivery of the software stack, including CAD ingestion, adaptive control, and vision-tactile tracking.
• A cross-program retasking report showing a switch between two harness families in under 8 hours.
• A technical data package with schematics, interface control documents, manuals, and MES/ERP integration guides.
• A final performance report from a live prime facility demonstration validating accuracy, force profiles, throughput, labor savings, and the digital thread.

How the Phases Are Structured

Phase I is skipped. Because this is Direct to Phase II, your proposal must prove feasibility already exists. The DAF will not consider a proposal that fails to show technical merit and feasibility, or whose feasibility was not substantially performed by your firm or principal investigator. Expected evidence includes empirical lab data and test logs from prior robotic manipulation of flexible parts, closeout reports from non-SBIR federal, academic, or internally funded flexible assembly work (the topic cites ARM Institute style projects), and an existing physical or digital single-arm prototype that runs on a cloud-independent edge loop at TRL 4 or higher.

Phase II integrates and validates the workcell in the lab, then in live TRL 7 pilot production testing at prime contractor facilities.

Phase III commercializes to government program offices, the industrial base, and dual-use manufacturers.

Funding and Proposal Limits

• Direct to Phase II award maximum: $2,000,000. Proposals above this amount will not be considered for evaluation or award.
• Award maximum duration: 24 months.
• Technical Volume (Volume 2) limit: 35 pages or slides.
• No Phase I awards will be made under this topic.
• TABA: DAF will provide up to $50,000 per Phase II award in addition to the topic amount, and you may split it 50/50 across a first and a sequential Phase II. The detailed request must be in Volume 5.

Who Is Eligible

• You must be a U.S. small business concern that meets SBIR ownership and size rules at the time of award.
• You must document that you already completed Phase I type feasibility work. That work must have been substantially performed by your firm or your principal investigator, and it cannot be based on or logically extend from any prior or ongoing federally funded SBIR or STTR work.
• Firms majority owned by multiple venture capital operating companies, hedge funds, or private equity funds are eligible to propose to DAF topics.
• DoW now limits proposals on a per-topic basis, so plan on one strong proposal for this topic.

Key Dates and How to Apply

• Now through October 28, 2026: pre-release. Topic authors are listed on the DSIP Topics and Topic Q&A page and you can call or email them directly with technical questions. This is the only window for direct contact.
• October 28, 2026: the topic opens for proposals in the Defense SBIR/STTR Innovation Portal (DSIP). After this date, questions go through DSIP Topic Q&A only.
• November 25, 2026 at 12:00 p.m. ET: complete proposals must be certified and submitted in DSIP. A proposal still marked In Progress or Ready to Certify is not considered submitted.
• Before you submit, confirm an active SAM.gov registration, a DSIP account, completed Volume 6 Fraud, Waste, and Abuse training, and the Volume 7 foreign affiliation disclosure webform.

Is This Topic a Fit for Your Company?

Robotics startups working on deformable object manipulation, cable routing, or tactile sensing are the target, especially those with existing industrial pilots. A partnership letter from a defense prime or UAS manufacturer willing to host the demonstration will strengthen the proposal considerably.

BW&CO has helped deep tech founders secure $350M+ in non-dilutive funding. If you want a second opinion on fit, feasibility documentation, or a proposal plan before the deadline, book a call with our team below.

Frequently Asked Questions

What is DAF SBIR topic DAF27BZ01-DV011?

It is a Department of the Air Force SBIR Direct to Phase II topic in DoW SBIR 2027 BAA Release 1 for an agile single-arm robotic workcell that autonomously installs flexible wire harnesses and connectors in UAS and munitions.

How much funding is available?

Up to $2,000,000 over up to 24 months, plus up to $50,000 in TABA per Phase II award if requested.

What performance targets matter most?

Insertion accuracy of 0.5 mm or better, at least 2x throughput over manual work, at least 50 percent labor hour reduction, retasking in under 8 hours, and full digital thread traceability.

What starting maturity is required?

A validated proof-of-concept software and mechanical baseline at TRL 4 or higher, supported by empirical data rather than concepts.

When is the deadline?

The topic opens October 28, 2026 and closes November 25, 2026 at 12:00 p.m. ET in DSIP.