DAF26BZ05-NV029: Cost-Effective Composite Joints with Tailorable Performance and Geometry

Below is a brief summary. Please check the full solicitation before applying (link in resources section).

Quick Answer

The Department of the Air Force is offering a Phase I SBIR award of up to $300,000 for companies developing scalable, cost-effective carbon fiber composite joint technologies with tailorable geometry for aerospace applications. This is topic DAF26BZ05-NV029 under the DoW FY26 SBIR BAA Release 5. Proposals are due September 23, 2026 through DSIP.

What This Solicitation Is

This is a standard Phase I SBIR topic, meaning applicants are proposing a feasibility study. It falls under the Scaled Hypersonics critical technology area, touching Advanced Materials and Advanced Infrastructure and Advanced Manufacturing as component priority areas. It carries a projected CMMC Level 2 (Self) requirement and is restricted under ITAR and EAR, requiring disclosure of any foreign national involvement.

This topic carries a higher award ceiling and longer duration than the other three Phase I topics in this release.

What DAF Is Looking For

Composite structural joints today force a tradeoff. Back-to-back "L" joints offer customizable geometry but lower mechanical performance, while 3D woven pi-joints offer higher structural integrity but limited design flexibility. Both are expensive and hard to scale for surge manufacturing. DAF wants a new approach to carbon fiber preform architectures and manufacturing processes that breaks that tradeoff, delivering joints that are both tailorable in geometry and strong in performance, at a cost point that supports mass production.

This matters most for Autonomous Collaborative Platforms and other advanced weapons systems, where affordable, high-capability autonomous air vehicles depend on being able to manufacture composite airframes at scale without sacrificing mechanical performance or driving up unit cost.

The proposed work starts at TRL 2, fundamental research into design space and material configurations, and targets TRL 6 by the end of Phase II, meaning validated prototypes demonstrated in a relevant operational environment. Phase I activities include a literature review and trade study benchmarking current composite joint solutions, design and fabrication of initial carbon fiber pi-joint test articles demonstrating novel fiber architectures or manufacturing processes, a preliminary process flow for converting dry fiber preforms into finished composite pi-joints, and a technical feasibility report covering proposed geometries, material configurations, and cost projections.

Phase II expands into optimizing fiber architectures for a broader design space, developing scalable preform manufacturing with advanced resin impregnation techniques, fabricating additional joint specimens for diverse operational scenarios including Autonomous Collaborative Platform applications, mechanical testing to validate performance, and cost models covering both low-rate initial production and high-rate surge production.

Funding and Timeline

Award maximum is $300,000 with a maximum period of performance of 9 months, both higher than the other three Phase I topics in this release. Proposals exceeding either figure will not be considered. The technical volume page limit is 20 pages.

DAF also provides up to $6,500 in Technical and Business Assistance funding per Phase I award, on top of the cost proposal total.

Proposals are due September 23, 2026 through DSIP. DAF anticipates evaluation and selection within roughly 90 calendar days of solicitation close.

Who Should Apply

This topic fits companies with composite materials manufacturing experience, particularly carbon fiber preform design, resin impregnation processes, or 3D weaving techniques for structural joints. Companies with existing aerospace composite manufacturing relationships or experience with automotive composite structures, where similar tradeoffs between cost, geometry, and performance apply, are well positioned. Since this starts at TRL 2, a credible design and manufacturing process concept matters more at this stage than a finished prototype, but real materials engineering depth will differentiate a strong proposal.

Eligibility and Compliance Notes

At least two thirds of the research effort must be performed by the awardee, measured by direct and indirect costs. All research and development work must happen in the United States except in rare, specifically approved circumstances.

Small businesses majority owned by multiple venture capital operating companies, hedge funds, or private equity funds are eligible to submit and receive awards under this Phase I BAA release.

Only one principal investigator can be designated per proposal, and their technical resume with publications must be included.

DAF runs a foreign risk evaluation and due diligence review on every proposal under 15 U.S.C. 638(vv).

Frequently Asked Questions

What is the proposal deadline?
September 23, 2026, submitted electronically through DSIP.

How much funding is available?
Up to $300,000 for a Phase I award with a maximum period of performance of 9 months, plus up to $6,500 in additional Technical and Business Assistance funding.

Why does this topic have a higher award ceiling than the other Phase I topics in this release?
The solicitation does not explain the difference, but the scope, spanning literature review, physical test article fabrication, and cost modeling across two production scenarios, is broader than the other three Phase I topics in this release.

What TRL is this starting from and targeting?
TRL 2 at Phase I start, targeting TRL 6 by the end of Phase II.

Are venture capital or private equity backed companies eligible?
Yes. This Phase I BAA release does not exclude VC, hedge fund, or private equity owned small businesses.

What is the page limit for the technical volume?
20 pages.

Is this topic export controlled?
Yes. It is restricted under both ITAR and the Export Administration Regulations, with disclosure required for any foreign national involvement.

What happens in Phase III?
Phase III advances the composite joint technology for military Autonomous Collaborative Platform airframes and advanced weapons systems, with commercial crossover into automotive and aerospace industries, focusing on preform optimization and surge production cost reduction.