DON26BZ05-DV084 — Innovative Flexible Fuel Cell Design
Below is a brief summary. Please check the full solicitation before applying (link in resources section).
Quick Answer
DON26BZ05-DV084 is a Navy Direct to Phase II (DP2) SBIR topic sponsored by NAVAIR. It funds advanced manufacturing processes and materials for producing Class A, Type I crashworthy, self-sealing aircraft fuel cells compliant with MIL-DTL-27422F, with a focus on faster production timelines and fewer defects. Maximum Phase II award across Base and Option is $1,400,000. Proposals are due September 23, 2026 (confirm against the official BAA posting).
Executive Summary
Aircraft fuel cells (fuel bladders) have to survive crash impacts, stay flexible enough to fold into tight airframe cavities during installation, and self-seal if punctured, all while meeting a decades-old but still governing specification, MIL-DTL-27422F. NAVAIR's problem is not the performance target itself but the production process behind it: current manufacturing takes months, and the Navy wants materials and processes that get fuel cells built in weeks instead, without sacrificing quality or increasing defect and rework rates.
The technical bar is specific. The finished fuel cell must remain lightweight, pliable, and foldable enough for installation into structural airframe cavities, while still withstanding crash impact loads at velocities of 65 feet per second. It must self-seal and continue operating at temperatures down to negative 40 degrees Fahrenheit and pressures of 1.5 psi. This is a materials and manufacturing engineering challenge as much as a design challenge, since the same fuel cell needs to be both flexible for installation and rugged enough to survive a crash.
Phase I feasibility here is comparatively lean relative to other topics in this release: NAVAIR asks for availability of material-level data and a defined proof of concept for fuel cell construction designs or applications that validates the approach. Companies with existing material characterization data and a credible construction concept are well positioned to qualify.
Phase II work aligns directly with MIL-DTL-27422F qualification activities, prioritizing crash impact, gunfire performance, and flexibility evaluation. Deliverables include material coupons, panels, and cubes, along with testing that demonstrates the materials and processes meet the spec.
Work is expected to become classified in Phase II, and the contractor must be able to obtain and maintain a secret facility clearance and personnel clearances. Phase III looks toward scaling to aircraft-representative articles and validating compliance on a rotary platform, with clear crossover potential into Foreign Military Sales and commercial aircraft, where NAVAIR notes FAA requirements are actually less stringent than the military standard this topic targets, making commercial adaptation comparatively straightforward.
Funding
Phase II Base: up to $1,000,000, period of performance up to 30 months
Phase II Option: up to $400,000, period of performance up to 12 months
Maximum total (Base plus Option): $1,400,000
No separate Phase I award is issued under DP2
Award types considered: Cost Plus Fixed Fee, Firm Fixed Price, Basic Ordering Agreement, or Prototype Other Transaction
Discretionary TABA available: up to $25,000 per award, included in the Phase II award amount
Timeline
Step one: submit a Phase I Feasibility Proposal through DSIP
Step two: if selected, the SYSCOM contacts the company directly with instructions to submit a Full DP2 Proposal
Proposal deadline: September 23, 2026 (verify against the official BAA close date for this release)
Notifications sent approximately one week after BAA close, based on the Cover Sheet email address
Key Requirements
Must demonstrate completed Phase I-type R&D independently, not solely from prior federal SBIR/STTR funding
Must show material-level data and a defined proof of concept for fuel cell construction
Must target compliance with MIL-DTL-27422F Class A, Type I requirements
Technical Volume limited to 30 pages total: 20 pages for Phase I feasibility, 10 pages for the Phase II snapshot
Minimum 50 percent of Phase II work performed by the proposing small business, in both Base and Option
CMMC Level 2 (Self) projected requirement
Must be able to obtain a secret facility clearance and personnel clearances for classified Phase II work
Point of Contact
Kristi DePriest, Naval Air Systems Command (NAVAIR)
navair-sbir@us.navy.mil
Frequently Asked Questions
What specification does this fuel cell need to meet?
MIL-DTL-27422F, for Class A, Type I crash-resistant, ballistic-tolerant aircraft fuel cells.
What is the main problem NAVAIR is trying to solve?
Current fuel cell manufacturing takes months. NAVAIR wants processes and materials that produce compliant fuel cells in weeks, without increasing defects or rework.
What performance must the fuel cell survive?
Crash impact loads at velocities of 65 feet per second, operation down to negative 40 degrees Fahrenheit, and pressures of 1.5 psi, while remaining flexible enough to fold into airframe cavities during installation.
What does NAVAIR expect for Phase I feasibility?
Availability of material-level data and a defined proof of concept for fuel cell construction designs or applications that validates the approach.
Does this require a security clearance?
Yes. Work is expected to become classified in Phase II, and the contractor must be able to obtain and maintain a secret facility clearance and personnel security clearances.
Is there a commercial or allied-nation application for this technology?
Yes. NAVAIR points to Foreign Military Sales and commercial aircraft applications, noting FAA requirements are less stringent than the military standard, which supports an easier commercial adaptation path.
How much can a Phase II award be worth?
Up to $1,000,000 for the Base and up to $400,000 for the Option, for a maximum of $1,400,000.
What is the proposal deadline?
September 23, 2026
