Domestic Production of Plant-based Carbon Fiber Precursors in Support of Hypersonic Applications - SBIR Topic DON26BZ04-NV066
Funding Amount:
$315,000
Deadline to Apply:
August 19th, 2026
ITAR:
The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.
Objective:
Develop an environmentally friendly processing method to produce a plant-based carbon fiber precursor for high-temperature applications.
Description:
Rayon-based carbon fibers remain the choice of material as reinforcement in carbon phenolic composites used as thermal protection systems for hypersonics.
Currently, rayon fiber precursors used to make rayon-based carbon fibers are not produced in the United States and are subject to the volatile global market for rayon fibers.
Moreover, rayon fibers are vital to other Department of Defense programs, NASA, and commercial space companies due to their proven superior thermal performance over polyacrylonitrile (PAN) and pitch-based carbon fibers [Ref 1].
The production of rayon fibers ceased in the United States in 1997 due to the increased cost associated with environmental concerns from the traditional viscose process to produce rayon fibers.
Since then, rayon fiber precursors have been sourced from European textile companies that primarily produce rayon for applications other than as a precursor for carbon fiber.
Among the 6.5 million metric tons of rayon fibers produced per year, approximately 1.6-3.2 metric kilotons are rayon fiber precursors used to make carbon fiber [Ref 2].
The global market for rayon is shifting toward a non-toxic process to produce rayon fibers; however, new rayon fibers and other plant-based (cellulose or lignin) fibers have yet to be proven as adequate precursors to produce carbon fibers for thermal protection systems.
Therefore, research on environmentally friendly processes to produce a rayon fiber precursor or another plant-based fiber is needed to establish a domestic source of carbon fiber precursor suitable for thermal protection systems.
The fiber precursor must be able to be carbonized into a carbon fiber and characterized for structure and properties.
Work produced in Phase II may become classified.
Note: The prospective contractor(s) must be U.S. owned and operated with no foreign influence as defined by 32 U.S.C. § 2004.20 et seq., National Industrial Security Program Executive Agent and Operating Manual, unless acceptable mitigating procedures can and have been implemented and approved by the Defense Counterintelligence and Security Agency (DCSA) formerly Defense Security Service (DSS).
The selected contractor must be able to acquire and maintain a secret level facility and Personnel Security Clearances.
This will allow contractor personnel to perform on advanced phases of this project as set forth by DCSA and NAVSEA in order to gain access to classified information pertaining to the national defense of the United States and its allies; this will be an inherent requirement.
The selected company will be required to safeguard classified material during the advanced phases of this contract IAW the National Industrial Security Program Operating Manual (NISPOM), which can be found at Title 32, Part 2004.20 of the Code of Federal Regulations.
PHASE I:
Develop a proof of concept for the processing of cellulose or lignin to produce a fiber precursor for the production of carbon fibers.
(Note: The fiber precursor is expected to be carbonized into a carbon fiber. The subsequent carbon fiber is expected to be characterized for break strength and carbon content.)
Ensure that the process meets Environmental Protection Agency standards for effluent from fiber processing in accordance with pertinent environmental regulations for the production of fibers.
The Phase I Option, if exercised, will include the initial design specifications and capabilities description to build a prototype solution in Phase II.
PHASE II:
Build upon the process identified during Phase I by weaving and carbonizing the fiber precursor to create a carbon fabric prototype.
(Note: For applicability into thermal protection systems, the fiber precursor can be woven into fabric prior to or after carbonization.)
Provide, at a minimum, the following characterization analysis of the prototype:
Electrical conductivity.
Density.
Char yield.
Break strength.
Alkali metal impurities content of the carbonized fabric.
It is probable that the work under this effort will be classified under Phase II (see Description for details).
PHASE III DUAL USE APPLICATIONS:
Scale the process in order to produce fiber precursors that can be woven, carbonized, and integrated into applicable polymer matrices to deliver a polymer matrix composite component for a thermal protection system.
Transition the composite to the Navy based on its thermal and ablative performance in an arc jet test.
Provide additional characterization such as the composite’s density, thermal conductivity, char yield, spectral emissivity, tensile strength, and shear strength.
Support the government in transitioning the technology for government use.
The transitioned product is expected to be able to support current and future weapon and space systems, as well as a wide range of other air-, land-, and sea-based systems.
The development of a domestic course of rayon-based carbon fibers would be of interest to the Army, Navy, Air Force, NASA, and commercial space programs for rocket nozzles and thermal protection systems.
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.
Request to talk with a member of our team by completing the form below: