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Topic DON27BZ02-NV007 from the DoW SBIR 2027 BAA, Release 2. Pre-release now; proposals due January 6, 2027, 12:00 PM ET.
Quick answer
DON27BZ02-NV007 is a Department of the Navy SBIR topic seeking a man-portable, self-contained nitrogen generator that produces high-purity, high-pressure nitrogen on 120-volt, 25-amp single-phase power for USMC expeditionary maintenance. It follows a standard Phase I concept and Phase II prototype structure. Proposals are due January 6, 2027, 12:00 PM ET.
Solicitation at a glance
- Topic number: DON27BZ02-NV007
- Official title: Lightweight, Energy-Efficient Portable Nitrogen Generator for Expeditionary Operations
- Agency: Department of the Navy
- Program: SBIR (DoW SBIR 2027 BAA, Release 2)
- Award type: Phase I (see topic text for Phase II)
- Award amount: Phase I base up to $200,000 plus an option up to $115,000. Source: Navy Release 2 instructions in DSIP.
- CMMC level: Level 2 (Self)
- ITAR: Yes. Export-controlled (ITAR/EAR); see topic text
- Technology areas: None
- Pre-release (direct TPOC contact allowed): November 4 to December 2, 2026, 8:00 AM ET
- Opens in DSIP: December 2, 2026, 8:00 AM ET
- Proposals due: January 6, 2027, 12:00 PM ET
- Official source: DSIP Topics app (search DON27BZ02-NV007)
BW&CO's take
What the Department of the Navy wants
Marines need high-pressure nitrogen at forward locations to service tires, recoil mechanisms, accumulators, and struts. The legacy generator weighs 450 pounds, needs 240-volt power, and reaches only 99.0% purity, while commercial 120-volt units exceed 650 pounds and need external compressors. The Navy wants a modular, self-contained unit with built-in air compression that runs within 120 VAC, 25 A limits, fits through a JEMS shelter door, and stays efficient in high heat and humidity. The Phase II threshold table lists no less than 3,500 PSI output, 99.5% purity, 60 SCFH continuous flow, 250 lbs total weight with a two-wheeled cart configuration, and modules within MIL-STD-1472 two-person lift limits (the table's comparison symbols are garbled in the source text). The prototype should also target an MTBF of at least 1,000 operating hours.
Who is a good fit
- Membrane or pressure swing adsorption gas separation experience, especially novel sorbents or hybrid architectures
- Compact high-pressure air compressor and electric motor design for limited single-phase power budgets
- Lightweight composite enclosures and modular packaging designed to human-factors lift limits
- Thermal and moisture management for equipment operating in high heat and humidity
Watch-outs
- Proposals must identify the selected nitrogen generation approach and give a credible technical basis for meeting the parameters, particularly thermal/moisture management and weight reduction, while showing awareness of the state of the art.
- Some numbers in the topic text are inconsistent: the Objective cites 1,800 to 3,500 PSI and purity 'equal to or less than 99.5%', the Phase II section says 'up to 3,500' PSI, and the Phase II table sets a threshold of no less than 3,500 PSI. The table's operating temperature threshold also reads '40°F' alongside -32°C. Confirm the intended values with the topic authors while direct contact is allowed (until December 2, 2026, 8:00 AM ET).
- The topic metadata marks it as ITAR-restricted, which generally limits foreign national participation.
- The topic metadata lists CMMC Level 2 (Self).
Think your company fits DON27BZ02-NV007? Talk with BW&CO before the January 6 deadline.
Plan Your DON27BZ02-NV007 Submission
Official topic text (verbatim from DSIP)
The text in this section is copied word for word from the official DSIP topic as published on November 4, 2026. DSIP is the official source and topics can be amended. Always confirm the current version at dodsbirsttr.mil before you submit. Our commentary above is BW&CO's interpretation, not Government guidance.
Title
Lightweight, Energy-Efficient Portable Nitrogen Generator for Expeditionary Operations
Objective
Develop and demonstrate a man-portable, self-contained nitrogen generator capable of producing high-purity (equal to or less than 99.5%) nitrogen at 1,800 to 3,500 pounds per square inch (PSI), operating strictly within a 120-volt, 25-Amp single-phase electrical limit to support United States Marine Corps (USMC) expeditionary maintenance operations. While utilizing common enabling gas-separation technologies similar to topic N244-P02, this effort is strictly distinguished by its unique requirement for a highly modular, lightweight, two-man portable form factor engineered specifically for point-of-need operations in austere, forward-deployed environments.
Description
The United States Marine Corps (USMC) requires high-pressure nitrogen gas at forward operating locations to perform essential maintenance tasks, including aircraft and ground vehicle tire servicing, recoil mechanism servicing, recharging of gas suspension and accumulator components, and filling gas cylinders. Historically, the military relies on pre-filled, heavy steel gas cylinders resupplied through a vulnerable logistics chain. This process creates a severe logistical burden and hazardous material handling risk. Generating nitrogen at the point of need is essential to sustaining mission readiness in distributed, austere, and expeditionary environments consistent with USMC Force Design 2030 and Expeditionary Advanced Base Operations (EABO) concepts. The final product will be employed by USMC maintainers operating from forward tactical enclosures, specifically integrating with the JLTV Electronic Maintenance Shelter (JEMS). The system will provide point-of-need, high-purity nitrogen to service tactical vehicle and aircraft tires, hydraulic accumulators, recoil mechanisms, and suspension struts in support of distributed expeditionary operations.
While the USMC currently utilizes a legacy portable nitrogen generation system, it presents severe technical limitations that hinder expeditionary operations. First, the legacy system weighs 450 pounds, severely limiting mobility and requiring a four-person lift. Second, it requires 240-volt single-phase electrical power drawing 25 Amps. This exceeds the standard 120-volt, 25-Amp electrical limits of forward tactical enclosures, such as the Joint Expeditionary Maintenance Shelter (JEMS). Third, the current system only achieves 99.0% nitrogen purity (falling short of the required 99.5% for sensitive aviation and vehicle struts) and suffers from extremely slow flow rates, taking up to 6 hours to fill a standard 244-cubic-foot cylinder.
Commercial industry has introduced 120-volt single-phase configurations that achieve high purity. However, these state-of-the-art commercial units fall short of expeditionary physical requirements: they weigh in excess of 650 pounds, require separate external air compressors to operate, and maximize output at only 3,000 pounds per square inch (PSI). No known existing solution simultaneously achieves man-portable weight limits, 120-volt/25-Amp operation, self-contained air compression, high purity (Develop and demonstrate a man-portable, self-contained nitrogen generator capable of producing high-purity (equal to or less than 99.5%) nitrogen at 1,800 to 3,500 pounds per square inch (PSI), operating strictly within a 120-volt, 25-Amp single-phase electrical limit to support United States Marine Corps (USMC) expeditionary maintenance operations.
This SBIR topic seeks innovative small business proposals to design, develop, demonstrate, and deliver a prototype device for a man-portable, energy-efficient, self-contained nitrogen generator that overcomes the stated limitations. Proposed approaches may include advanced membrane separation, pressure swing adsorption (PSA) with novel sorbent materials, hybrid separation architectures, lightweight composite enclosures, advanced electric motor/compressor technologies, intelligent power management, or other innovative approaches that meaningfully advance the state of the art. The prototype device must address extreme environmental challenges, specifically maintaining gas separation efficiency in high heat and high humidity, and must physically fit within tactical maintenance shelters.
The prototype device shall target the following performance parameters to bound the scope of effort, while remaining open to innovative approaches that may refine specific parameters:
Performance Parameter Phase II Threshold (T = Minimum Acceptable) Phase II Objective (O = Desired)
Output Pressure (Selectable/Continuous): No less than 3,500 PSI (T); Greater than 3500 PSI (O)
Nitrogen Purity: =/- 99.5% (T); =/- 99.99% (O)
Continuous Output Flow Rate: =/- 60 Standard Cubic Feet per Hour (SCFH) (T); =/- 120 SCFH (O)
System Weight & Transportability: =/+ 250 lbs total. Must include two-wheeled cart configuration. System can break down into modular components where no single module exceeds the two-person lift limits defined in MIL-STD-1472 (T); =/+ 150 lbs total. System can break down into modular components where no single module exceeds the two-person lift limits defined in MIL-STD-1472 (O)
Form Factor/Size Limits: Must physically clear a 51.5 in (W) x 64.5 in (H) shelter door Modular, compact footprint (e.g., =/+ 30 in x 30 in base) (T = O)
Electrical Power Input: =/+ 3.4 kW, 120 VAC (single-phase, 50-60 Hz, max 25-Amp draw) (T): =/+ 3 kW, 120 VAC (single-phase) AND/OR 28V DC (Tactical Vehicle Integration) (O)
Operational Temperature: 40°F to +90°F (-32°C to +49°C) (T); -40°F to +140°F (-40°C to +60°C) (O)
Operational Humidity: Operable in 0% to 95% Relative Humidity (RH) (T); Operable in up to 100% RH (condensing) (O)
Proposals shall clearly identify the selected nitrogen generation approach, provide a credible technical basis for meeting the target performance parameters (particularly regarding thermal/moisture management and weight reduction), demonstrate awareness of the state of the art, and demonstrate that the effort is achievable within SBIR Phase I and Phase II timelines.
Phase I
Define and develop a conceptual approach to portable high-pressure nitrogen generation that meaningfully advances beyond the current state of the art, with particular emphasis on achieving significant weight reduction (via modularity), self-contained air compression, and thermal/moisture management in expeditionary environments. Determine the technical feasibility of the conceptualized man-portable, self-contained nitrogen generator.
Perform modeling and simulation to predict prototype device performance against the parameters defined in the Description. Develop engineering approaches to address key technical challenges, including modular enclosure design to meet MIL-STD-1472 lift limits, high-efficiency nitrogen separation (e.g., advanced membranes or PSA sorbents) at reduced power input, and intelligent power management to ensure seamless integration with the Joint Light Tactical Vehicle (JLTV) Expeditionary Maintenance Shelter (JEMS) Power Entry Panel. Identify and assess critical technical risks associated with the proposed approach and define mitigation strategies.
Deliver the following required Phase I deliverables: a final technical report documenting the proposed conceptual design, modeling and simulation results, technology trade space analysis, technical risk assessment, and a recommended path forward for Phase II prototype device development.
Phase II
Based on the conceptual design, modeling and simulation results, and technical feasibility findings from Phase I, design, fabricate, and validate a prototype man-portable, self-contained, energy-efficient portable nitrogen generator capable of producing high-purity nitrogen (=/- 99.5%) at up to 3,500 pounds per square inch (PSI) output pressure on 120-volt, 25-Amp single-phase electrical power in support of United States Marine Corps (USMC) expeditionary maintenance operations.
Demonstrate and validate the prototype device against the performance parameters defined in the Description, with particular emphasis on modularity to meet MIL-STD-1472 two-person lift limits, single-phase power consumption, output pressure range, nitrogen purity, and operational flow rate in high heat and high humidity environments. To guide prototype development and ensure suitability for long-duration expeditionary deployments, the prototype design should target a Mean Time Between Failure (MTBF) of no less than 1,000 operating hours, and scheduled preventive maintenance intervals (e.g., filter or seal replacements) of no less than 250 operating hours Fabricate and validate the prototype device through laboratory testing and, where feasible, demonstration in a tactically representative expeditionary environment in coordination with USMC end-user representatives.
Develop and validate the manufacturability process for the prototype device, identify critical components and supply chain considerations, and produce a Phase III transition plan identifying the target acquisition program, production pathway, and dual-use commercialization strategy.
Deliver the following required Phase II deliverables: a functional prototype device, a comprehensive test and evaluation report documenting measured performance against Threshold and Objective parameters defined in the Description, and a Phase III transition plan.
Phase III Dual Use Applications
The expected final state of this technology is a fully validated, production-ready, man-portable expeditionary nitrogen generator. Upon successful completion of Phase II, support Phase III transition of the prototype device to the Product Manager Maintenance Support Systems (PdM MSS), under Program Manager Combat Support Systems (PM CSS) at Marine Corps Systems Command (MCSC). Assist with formal integration of the nitrogen generator into the Tool Sets and Kits Program of Record as a direct replacement for the legacy High-Pressure Deployable (HPCD) system.
In addition to the primary military transition path, the new nitrogen generator has substantial commercialization potential. A lightweight, 120V single-phase, high-pressure (3,500 PSI) nitrogen generator that does not require heavy industrial power or external air compressors has direct applicability in several commercial sectors, including remote commercial aviation maintenance (e.g., servicing landing gear struts and tires at austere airstrips), the automotive and off-road racing industry for high-performance shock absorber tuning, and remote heavy industry such as mining, agriculture, and oil/gas exploration, where transporting heavy, pre-filled nitrogen cylinders is costly and logistically prohibitive.
References
“Commercial Item Description (CID) A-A-59503E: Nitrogen, Technical (4 June 2025).” https://everyspec.com/COMML_ITEM_DESC/A-A-59000_A-A-59999/A-A-59503_31795/
“MIL-STD-1472H: Department of Defense Design Criteria Standard, Human Engineering (15 Sep 2020).” https://everyspec.com/MIL-STD/MIL-STD-1400-1499/MIL-STD-1472H_57041/
“MIL-STD-810H: Department of Defense Test Method Standard, Environmental Engineering Considerations and Laboratory Tests (31 Jan 2019).” https://everyspec.com/MIL-STD/MIL-STD-0800-0899/MIL-STD-810H_5598/
Keywords
Nitrogen; Generation; Portable; Adsorption; Gas; High-pressure; Single-phase power; Maintenance; Expeditionary
Frequently asked questions
What is DON27BZ02-NV007?
It is a Department of the Navy SBIR topic to develop and demonstrate a lightweight, energy-efficient, man-portable nitrogen generator for USMC expeditionary maintenance, intended to integrate with forward tactical maintenance shelters.
When is DON27BZ02-NV007 due?
Proposals are due January 6, 2027, 12:00 PM ET. DSIP pre-release began November 4, 2026, and direct contact with the topic authors is allowed only until the topic opens on December 2, 2026, 8:00 AM ET.
Is this a Phase I or Direct-to-Phase II topic?
The topic describes a Phase I conceptual design with modeling, simulation, trade space analysis, and risk assessment, followed by Phase II prototype fabrication and validation. It is not labeled Direct-to-Phase II.
What reliability targets apply to the Phase II prototype?
The prototype design should target a Mean Time Between Failure of no less than 1,000 operating hours and scheduled preventive maintenance intervals, such as filter or seal replacements, of no less than 250 operating hours.