Field Deployable Welding Technologies for In-Situ Repair of Thermoplastic Composites Components on Naval Aviation Platforms - STTR Topic DON26TZ01-NV011
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This topic was temporarily posted by the Department of War SBIR Program on March 2nd 2026 and removed the following day.
We believe this topic is planned to be released once the SBIR program is reauthorized; however, this topic may ultimately be modified or withdrawn.
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Funding Amount:
Est. $240,000
Deadline to Apply:
Est. April 29th, 2026.
Objective:
Develop and transition a portable induction welding system capable of in-situ repair of thermoplastic composite components on naval aviation platforms enabling rapid, field-ready maintenance capabilities for next-generation naval aircraft.
Description:
Modern aviation platforms are increasingly using high-performance thermoplastic composites such as PAEK, PEEK, PPS, or PEI reinforced with Carbon Fiber for structural and semi-structural components. Their attractiveness is due to their superior damage tolerance, impact, and ability to be reworked for repair. Unlike traditional thermoset composites, which can only be repaired by bonded patches or bolted panels, thermoplastic composites can also be repaired by welding, which restores strength without the need to remove additional material. However, currently available welding systems have a large footprint and are available mostly with OEM and only suited for deployment at the Depots. Thus, without field deployable technofixes, repairs will result in long downtime for repair and likely higher scrap rates.
This STTR topic seeks to leverage the research expertise of academic or government labs in thermoplastic processing and electromagnetic heating to partner with a small business in designing a rugged, portable induction welding system that can be deployed shipboard and/or in Aircraft Intermediate Maintenance Detachments.
The proposed system should: (1) be capable of welding aerospace-grade thermoplastics (at temperatures up to 400°C); (2) be lightweight and field operable, including on aircraft carriers; (3) be electromechanically ruggedized and safe to operate near avionics and flight-critical systems; (4) have a closed-loop thermal control for temperature; (5) be able to repair skins, fairings, panels, and access doors; and (6) have a weld strength of at least 70% of the parent material.
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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