Next-Generation Non-Lithium Battery Technology for Safe, Extreme-Environment, High-Performance Resilient Military Logistics and Field Operations - SBIR Topic DLA26BZ03-NV013

Funding Amount:

Est. $100,000

Deadline to Apply:

July 22nd, 2026

Objective:

Develop and demonstrate a non-lithium battery cell and/or prototype battery pack capable of supporting BB-2590/U-class applications, with emphasis on safety, transportability, and domestic manufacturability, while achieving mission-relevant performance thresholds.

Description:

DLA’s current battery portfolio, including the widely fielded BB-2590/U rechargeable battery (NSN: 6140-01-490-4316), relies heavily on lithium-ion chemistries with significant exposure to foreign (including Chinese-origin) supply chains. Section 154 of the FY2024 NDAA restricts DoD procurement from certain foreign sources beginning in October 2027, creating an urgent need for compliant alternatives.

Beyond supply chain risk, lithium-based batteries present operational challenges including hazardous material classification for transport, thermal runaway risks, limited long-duration storage performance, and handling complexity in forward-deployed environments.

DLA requires a non-lithium battery solution that can support BB-2590/U-class applications while improving:

• Safety: Reduced or eliminated thermal runaway risk 

• Transportability: Less restrictive hazardous material classification and simplified logistics handling 

• Storage Readiness: Low self-discharge and long-duration storage (≥12–24 months) 

• Operational Performance: Reliable function across -30°C to +60°C environments 

• Durability: Resistance to shock, vibration, and field conditions 

• Supply Chain: Fully domestic or NDAA-compliant sourcing 

Solutions may not need to exceed lithium-ion performance in all areas but must demonstrate clear operational advantages in safety, logistics, or sustainment.

Performance Targets:

Proposed solutions should aim to meet or approach:

• Energy Density: ≥150 Wh/kg (threshold), ≥200 Wh/kg (objective) 

• Cycle Life: ≥500 cycles to 80% capacity 

• Storage Life: ≥12 months with minimal degradation 

• Operating Temperature: -30°C to +60°C 

• Safety: No thermal runaway under standard abuse conditions 

• Transport: Reduced hazardous classification compared to Li-ion (if applicable)

• MIL-STD environmental qualification testing covering temperature, vibration, and mechanical shock

• Preliminary safety qualification aligned with MIL-PRF-32383/3

• Validated domestic bill of materials demonstrating NDAA-compliant manufacturability

• Commercialization plan and domestic manufacturing roadmap with cost-per-unit projections at production volume

Scope

Phase I (6 months, up to $100K)

Focus on cell-level feasibility and trade-space validation:

• Demonstrate a non-lithium electrochemical system with initial performance data 

• Characterize:

  • Energy density (Wh/kg, Wh/L) 

  • Cycle life projections 

  • Voltage profile and discharge characteristics 

  • Temperature performance 

• Conduct preliminary safety testing, including abuse tolerance 

• Perform storage/self-discharge testing 

• Provide:

  • Concept for integration into BB-2590/U-class form factor 

  • Initial domestic supply chain assessment 

  • Phase II development plan 

Phase II (18 months, up to $1M)

Focus on prototype demonstration and transition readiness:

• Develop a prototype battery module or pack aligned with BB-2590/U electrical requirements 

• Conduct:

  • Environmental testing (temperature, shock, vibration) 

  • Extended cycle and storage validation 

  • Safety characterization aligned with military battery standards 

• Deliver:

  • Prototype system demonstration 

  • Validated domestic Bill of Materials 

  • Manufacturing feasibility and cost model 

  • Transition plan including pathway to qualification and DLA procurement

PHASE I

Phase I Deliverables (up to 6 months, up to $100,000)

The Phase I effort will establish the core technical feasibility of the proposed non-lithium battery chemistry through systematic cell characterization and safety testing. The following deliverables are expected:

Electrochemical Characterization: Prototype cells at a relevant form factor shall be characterized and tested, with performance data reported for energy density in Wh/kg and Wh/L, cycle life to 80% capacity retention, nominal voltage, and operational temperature range across both cold and high-heat conditions.

Safety Testing: Thermal stability characterization shall be conducted to demonstrate the absence of thermal runaway response under representative charge, discharge, and abuse conditions, establishing the fundamental safety advantage of the proposed chemistry over conventional lithium-based systems.

Self-Discharge Assessment: A storage stability assessment shall be conducted to measure self-discharge rates over a defined period, providing quantitative data to evaluate the technology's potential for reducing infrastructure overhead associated with long-term DLA war-reserve and pre-positioned stock storage.

PHASE II

Phase II Deliverables (18 months, up to $1,000,000)

Building on the Phase I feasibility demonstration, Phase II will advance the technology to a battery pack level and generate the qualification and commercialization data required for DLA procurement consideration. The following deliverables are expected:

•  Scaled Battery Pack Prototype: A fully integrated battery pack prototype shall be developed meeting the form factor and electrical specifications of target DLA battery applications, demonstrating the scalability of the Phase I cell technology to a system-level configuration.

•  MIL-STD Environmental Testing: The prototype shall be subjected to MIL-STD environmental qualification testing covering operational temperature performance and mechanical vibration, demonstrating suitability for deployment across diverse military platforms and environments.

•  Preliminary Safety Qualification: Safety qualification data shall be generated in alignment with applicable MIL-PRF specifications, providing DLA and its program offices with a preliminary compliance baseline for procurement and fielding consideration.

•  Validated Bill of Materials: A validated bill of materials shall be developed demonstrating the domestic manufacturability of the battery system, supporting DLA's interest in building a resilient and accessible domestic supply base for next-generation battery technologies.

•  Commercialization Plan and Manufacturing Roadmap: A detailed commercialization plan and domestic manufacturing roadmap shall be delivered, including cost-per-unit projections at production volume, outlining the pathway for transitioning the technology from prototype to DLA-procurable supply item and broader commercial markets — including heavy-duty vehicle electrification, maritime autonomous systems, and stationary grid-scale energy storage.

PHASE III DUAL USE APPLICATIONS

This technology has strong dual-use potential across both defense and commercial markets.

Defense Applications:

•  Man-portable communications systems

•  Unmanned systems (UGV/UAS)

•  Expeditionary sensors and electronic warfare systems

•  Pre-positioned war reserve energy storage

Commercial Applications:

•  Industrial and warehouse robotics

•  Remote sensing and IoT systems

•  Medical and safety-critical portable devices

•  Backup and stationary energy storage systems

•  Maritime and off-grid energy solutions

The emphasis on safety, long storage life, and simplified logistics positions non-lithium technologies as attractive alternatives in markets where lithium-ion risks or transport constraints are limiting factors.

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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