Adaptive Manufacturing and Integration at Scale (10^n)
Executive Summary:
The Department of War (using the DIU Commercial Solutions Opening process) is seeking commercial prototypes that demonstrate responsive, adaptive, and scalable production methods (e.g., digital design, AI-enabled software, 3D printing, CNC, automated molding, software-defined manufacturing) to create a resilient domestic space supply chain capable of on-demand production at unprecedented scale.
Responses are due by November 21, 2025, meaning companies should begin preparing today and seek additional help in order to meet this deadline.
How much funding would I receive?
Funding levels are not pre-set. Awards are made under Other Transaction (OT) authority, which allows the government to negotiate prototype agreements of varying scale based on project scope and relevance. Vendors selected for Phase 2 will provide a Rough Order of Magnitude (ROM) cost estimate. Follow-on production contracts—potentially of significantly larger magnitude—may be awarded without further competition if the prototype is successful.
What could I use the funding for?
Background and Problem Statement: The current domestic space supply chain, is oriented towards low-volume, exquisite production of bespoke components for highly specialized spacecraft. This model involves long lead times, high costs, and minimal bench stock. Suppliers are typically small and specialized entities that produce components in units of tens, not hundreds or thousands.
This legacy approach cannot meet current demand, which is driven by a dramatic increase in heavy lift launch capacity, cadence (trending towards a launch every day), and the need for proliferated satellite architectures. The existing exquisite supply chain will not scale without significant government investment and is unlikely to achieve the production levels needed to support the warfighter in times of conflict.
In response, the Department of War (DoW) is seeking commercial solutions to address production rate and capacity challenges in the U.S. space supply chain. This initiative aims to leverage digital design, AI-enabled software, adaptive manufacturing, and agile testing to rapidly produce dual- use space systems on demand and at commercial scale. Developing responsive, scalable and affordable space systems is critical for maintaining U.S. technological leadership in the space domain.
The Desired Solution and Key Objectives
The DoW seeks commercial solutions to prototype and demonstrate responsive and adaptive production methods (e.g., design for manufacturing (DFM), artificial intelligence (AI), 3D printing, computer numerical control (CNC), automated molding, software-defined manufacturing) with the goal of creating a resilient, adaptive, and agile domestic space supply chain capable of on-demand production at an unprecedented scale.
Key objectives include:
Achieve economies of scale in the U.S. space supply chain
Disrupt DoW’s dependence on exquisite sources of parts requiring long lead times
Demonstrate on-demand production rates of hundreds of units per month (10²/mo) to thousands per year (≥10³/yr).
Team commercial suppliers, advanced manufacturers, and defense integrators to address critical supply chain shortfalls as appropriate.
Accelerate the advancement of space manufacturing readiness level (MRL).
Employ an agile Design-Build-Test and Validate/Qualify iterative process to retain technological relevance.
Participant Roles
We will form teaming arrangements from the down-selected companies to collectively meet the needs of this AOI through an iterative process of digital design, adaptive building, operational test, and independent qualification.
Companies applying should identify with one of the following roles:
Defense Integrators: Defense contractors with a successful history of executing DoW contracts for system-level production units (e.g., spacecraft, aerospace systems).
Adaptive Manufacturers: Established companies experienced in scaling design-to-production throughput, including smart factories and agile supply chains.
Disruptive Innovators: Companies of any size that have developed disruptive technologies or manufacturing capabilities that enable economies of scale (e.g., unique software, robotics, AI algorithms).
Success will be measured by the DoW’s ability to demonstrate substantial economies of scale in the mass production and integration of critical space components and systems.
Mandatory Attributes:
Must have an established production capability (e.g. technology, process, or facility) to meet the specified production rates (10²/mo or 10³/yr).
Must be able to collaborate digitally throughout all prototype phases.
Must be agile and able to source components at the speed of relevance.
Defense Integrators must be willing to team with selected commercial companies.
Desired Attributes for Compelling Solutions:
Ready to produce key elements of flight-ready hardware within 3 months of the award.
Designed for autonomous operation.
Produced domestically or via friendly foreign supply chains.
Responsive and cost-effective at production scale.
Solutions should be commercially viable independent of this specific government use case.
Product/Capabilities Exemplars
There are known critical space manufacturing supply chain bottlenecks and these challenges range from Tier 1 Systems, Tier 2 Sub Systems, Tier 3 Assemblies, Tier 4 Components and Parts, or Tier 5 Hardware and Materials. Examples include, but are not limited to, propulsion tanks, power supplies, star trackers, thrusters, rad-hard electronics, batteries, modems, crypto, harnesses, and/or domestic commodities production for space applications. It is anticipated that defense integrators include discussion of Tier 1 and Tier 2 supply chain bottleneck solutions while adaptive manufacturers and disruptive innovators can highlight specific Tier 3, 4, and 5 products/capabilities they consider candidates for this CSO. Capabilities that enable scaled production rates (10²/mo or 10³/yr) are an example.
Are there any additional benefits I would receive?
Beyond the direct funding, participation offers major strategic advantages:
Government Validation and Credibility:
Selection through the DIU CSO process signals that your company’s industrialized construction approach meets urgent defense infrastructure modernization goals. That endorsement strengthens credibility with defense primes, base infrastructure offices, and private investors.
Enhanced Market Visibility and Notoriety:
Awardees gain visibility through DIU announcements, government communications, and defense industry press—establishing your firm as a recognized innovator in resilient military housing and off-site manufacturing.
Follow-On Production Opportunities:
Successful prototypes can transition directly to follow-on production agreements without further competition, potentially unlocking multi-installation, multi-year build programs.
Nondilutive Growth and Exit Value:
Winning an OT award provides nondilutive capital and validation, often leading to higher valuations and stronger acquisition potential for defense and construction-tech firms.
What is the timeline to apply and when would I receive funding?
Phase 1 Submission Deadline: November 21, 2025 (11:59 PM ET)
Phase 2 Pitches
Phase 3 Full Proposals
Awards: Prototype OT agreements are often executed within 60–90 days of selection under the above process.
Where does this funding come from?
Funding is provided through the Department of War (DoW) under the Defense Innovation Unit (DIU) using Other Transaction (OT) authority (10 U.S.C. § 4022). This allows flexible, competitive awards to commercial vendors outside of traditional Federal Acquisition Regulations (FAR).
Who is eligible to apply?
Eligible applicants include:
Defense Integrators – Established DoD contractors capable of system-level production and integration.
Adaptive Manufacturers – Companies experienced in high-throughput, smart, or autonomous production systems.
Disruptive Innovators – Any company (including startups and SMEs) offering breakthrough technologies that enable large-scale or cost-efficient production, such as AI-driven design or robotic manufacturing.
What companies and projects are likely to win?
Defense Integrators:
Have a track record of successful DoD system-level production (e.g., spacecraft or aerospace systems).
Present clear plans to integrate adaptive manufacturers and innovators into their production pipelines.
Address Tier 1 and Tier 2 bottlenecks such as propulsion systems, payload integration, or power architectures.
Demonstrate the ability to rapidly qualify and field flight-ready units at scale.
Adaptive Manufacturers:
Operate established or emerging smart factories capable of scaling throughput from tens to hundreds or thousands of units per year.
Showcase agile, AI-enabled, or software-defined production methods (e.g., CNC automation, additive manufacturing, digital twins).
Emphasize cost-efficient, domestic, and responsive production capacity.
Target Tier 3 and Tier 4 assemblies or components where scale and speed are critical.
Disruptive Innovators:
Bring novel technologies or processes that could redefine production economics (e.g., new materials, robotics, or design automation tools).
Demonstrate a path to integration with larger production ecosystems via teaming with integrators or manufacturers.
Highlight proof-of-concept or prototype performance showing transformative potential for space manufacturing readiness.
Focus on Tier 4 and Tier 5 hardware and materials, such as rad-hard electronics, sensors, or propulsion subcomponents.
Are there any restrictions I should know about?
All production must be domestic or via allied supply chains.
Companies must comply with ITAR and DoD security requirements.
Participants must be able to share and collaborate digitally throughout prototype phases.
Defense integrators are required to team with selected commercial companies.
How long will it take me to prepare an application?
For a first-time applicant, preparing a competitive solutions brief will take 50-75 hours in total.
How can BW&CO help?
Our team specializes in complex federal R&D proposals and can:
Triple your likelihood of success through proven strategy and insider-aligned proposal development
Reduce your time spent on the proposal by 50–80%, letting your team focus on technology and operations
Ensure you are targeting the best opportunity for your project and positioning your company for long-term growth.
How much would BW&CO Charge?
Our full service support is available for the Solution Brief for $5000. Pitch & Full proposal quoted upon invitation.
Fractional support is $300 per hour.
For startups, we offer a discounted rate of $250 per hour to make top-tier grant consulting more accessible while maintaining the same level of strategic guidance and proposal quality.
Additional Resources
View the Solicitation Here.