Open Architecture OEM Real-time Ultrafine Particulate Sensor - SBIR Topic DHA26BZ03-NV007

Funding Amount:

Est. $300,000

Deadline to Apply:

July 22nd, 2026

Objective:

Develop and demonstrate the efficacy of a low size, weight, power, and cost, and open-architecture ultrafine particulate sensor with real-time detection down to 0.01 microns (10 nanometers) or less at concentrations up to 10^6 particles per cubic centimeter.

Description:

This SBIR topic aligns with the DHA Environmental Exposures Toxic Injury Prevention Roadmap, specifically focusing on enhanced tools and assessment methodology for acute and chronic exposure to military-relevant chemicals, materials, and hazards.

Ultrafine particulates pose a significant health risk due to their ability to penetrate deep into the lungs, enter the bloodstream, and translocate to the brain. Exposure has been correlated with exacerbating asthma, cardiopulmonary disease and systemic effects (1). However, current mass-based exposure assessment standards are inadequate for characterizing the risks associated with these low-mass, high-surface-area particles and mixtures. The DoW currently lacks a detection capability to comprehensively characterize a service member’s exposure to ultrafine particulates, which results in the inability to evaluate potential correlation with health outcomes. Ultrafine particulates of interest for occupational monitoring include those generated from high intensity processes such as weapons firing, engine emissions and fires (2-3). Submicron particulate exposure in occupational environments with these emission sources is highly variable and depends on proximity to the source and airflow conditions, which necessitates personal breathing zone monitoring (i.e. affordable sensors). The peak size of particulates generated from these processes are less than 0.1 microns (100 nanometers). Most commercially available Original Equipment Manufacturer (OEM) particulate matter sensors use an optical measurement approach, which limits the lower size that can be detected to about 0.3 microns. Currently available direct reading instruments for measuring particulates less than 0.3 microns in real-time include condensation particle counters and electrometers, which are expensive (>$10K). Most are not available as an OEM version to be integrated with other sensors. Those that are available suffer from a relatively low upper concentration limit (10^5 particles per cubic centimeter) so cannot be used in the field for emission exposure measurements, where concentrations are often closer to 10^6 particles per cubic centimeter or higher (4).

Developing a comprehensive detection capability for ultrafine particulates is a critical investment in the long-term readiness and well-being of the force. Standard monitoring equipment often fails to detect submicron particles, which pose a medical threat due to their ability to penetrate the respiratory and cardiovascular systems. Service members operating in environments such as burn pits, flightlines/flight decks, or industrial maintenance facilities may be exposed to hazardous concentrations without warning, leading to systemic inflammation, cardiovascular stress, and respiratory toxicity. Proactive, quantitative surveillance provides data to allow commanders to make informed decisions to protect the force, enables preventative medicine personnel to mitigate hazards, and creates a permanent exposure data health record essential for future service member and veteran health care.

The novel materiel solution desired is a low size, weight, power and cost OEM ultrafine particulate sensor with real-time detection down to 0.01 microns (10 nanometers) or less at concentrations up to 10^6 particles per cubic centimeter. Individual sensors must be <$1K and have an open architecture that will allow for end user integration with other sensors or devices. The sensor must be ruggedized to meet requirements in MIL-STD-810H (5). In addition to the sensor, a solution to test calibration status in the field must also be developed. The development of the sensor and bump test solution must be coupled with a demonstration of efficacy to meet the stated requirements as well as repeatability in manufacturing consistency and performance across multiple sensors. Reliance on consumable materials such as working fluids should be minimized.

PHASE I

The Phase I effort will focus on a determination of a technological approach and proof of feasibility for developing a low cost (<$1K) OEM ultrafine particulate sensor that meets the required specifications, including ability to measure down to at least 0.01 microns (10 nanometers) at concentrations up to 10^6 particles per cubic centimeter with sensor response time of one second and accuracy of ±10% and sensor stability for at least one year. The feasibility analysis can include a review of currently available technology and analysis of components that can be simplified, miniaturized or eliminated while maintaining performance. The technical approach description shall also include an analysis of strategies for maximizing accuracy and stability in a broad range of environments as well as a preliminary design. A solution for field accuracy checks with minimal consumables and logistics requirements shall also be included.

PHASE II

The Phase II effort will include the development of three to five prototype devices and a robust performance evaluation to determine sensor accuracy when exposed to different ultrafine particulate emission sources at a broad range of environmental conditions, including -26 to +109 degrees Fahrenheit and 0 to 95% humidity (5). Sensor accuracy, response time and stability over time as a function of particulate source and concentration across 3-5 copies should be evaluated. The operational range for temperature, humidity and pressure shall be reported. Phase II will also include the development of a plan for scaling the manufacturing of the sensor with estimated per sensor cost. Finally, the ability to evaluate sensor accuracy in the field must also be demonstrated.

PHASE III DUAL USE APPLICATIONS

The envisioned end state is an OEM ultrafine particulate sensor that reliably measures particulates < 0.01 – 0.3 microns and can be sold commercially as a compliment to currently available optical sensors which typically measures particulates in the 0.3 – 10 micron size range. To achieve this end state, phase III efforts should include further hardware refinement for manufacturability, software refinement to ensure useability and technology demonstration in a broad range of field environments and conditions. Development via both private and military sectors should be investigated. Commercial applications where this capability may be used include wildfire response, manufacturing facilities, construction sites, airport flightlines, medical facilities and firing ranges to both assess and document worker exposure levels but also to evaluate the efficacy of controls. Development through government pathways may be considered in support of joint defense and medical modernization applications including comprehensive exposure monitoring and threat detection.

Who will win?

If you can achieve the objective above better than any other company on the market, you have a very high-likelihood of success and should apply.

Who is eligible to apply?

Any company that meets the following criteria:

• For-profit company

• U.S.-owned and controlled.

• 500 or fewer employees (including affiliates)

How Can BW&CO Help?

1) End-to-end support including, strategy, writing of the full proposal, and administrative & compliance support.

2) Proposal strategy and review.

3) Administrative & compliance support.

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