DON26BZ05-DV086 — Customized Aerospace Lightweight, High Power, High Frequency Bandwidth, Nanocrystalline EMI Filters
Below is a brief summary. Please check the full solicitation before applying (link in resources section).
Quick Answer
DON26BZ05-DV086 is a Navy Direct to Phase II (DP2) SBIR topic sponsored by NAVAIR. It funds development of lightweight, high power, high frequency bandwidth EMI filters using nanocrystalline core materials for aerospace power generation systems, targeting more than a 50 percent weight reduction compared to existing commercial off-the-shelf filters. 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
As the Navy pushes toward more electrified aircraft power and propulsion systems, it is leaning heavily on wide bandgap power conversion technology to get there. That technology solves one problem and creates another: it introduces significant electromagnetic interference and compatibility challenges that, if left unaddressed, can degrade avionics or mission systems and put warfighting readiness at risk. NAVAIR's answer is a better filter, specifically a common mode voltage cancellation EMI filter built around nanocrystalline core materials.
Nanocrystalline materials are attractive here because of their high saturation flux density, high temperature tolerance, and low core losses, all of which translate into weight savings for common mode inductors. The catch is that existing commercial nanocrystalline cores were built for different use cases: high power at low frequency for industrial drives, or low power at high frequency for radio frequency systems. Military aerospace applications need both high power and high frequency bandwidth simultaneously, which existing commercial parts do not deliver, and the power density and EMI requirements are notably more stringent than what commercial electric vehicle components are designed to meet.
The performance target is concrete and easy to evaluate: greater than 50 percent weight reduction compared to existing COTS CMVC filter and inductor components, achieved through customized high power, high frequency bandwidth nanocrystalline core materials, while still meeting EMI performance requirements defined in DO-160 and MIL-STD-461.
Phase I feasibility here is about materials pedigree: NAVAIR expects proposers to demonstrate real experience developing, manufacturing, and testing passive nanocrystalline magnetic core materials across various end-use applications, along with the technical depth to integrate those materials into CMVC EMI filter devices. This is a topic suited to companies with an existing materials science and magnetics engineering base, not a systems integration play.
Phase II is structured around Technology Readiness Level maturation: reach TRL 5 through lab testing and demonstration as a threshold requirement, then push to TRL 6 in a relevant end-use environment, while designing to both DO-160 and MIL-STD-461. The deliverable is concrete: at least two CMVC EMI filter units, each demonstrating the targeted weight reduction along with measurable improvements in filter attenuation.
Phase III moves toward flight-representative prototypes integrated into an aerospace generator or power system, with ground and flight test. NAVAIR notes the dual-use case directly: commercial aerospace faces the same demanding size, weight, power, and cooling constraints alongside similarly strict EMI and EMC requirements, making this a technology with a real path outside the military market.
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 prior experience developing, manufacturing, and testing passive nanocrystalline magnetic core materials
Must target greater than 50 percent weight reduction versus existing COTS CMVC filters
Must design to DO-160 and MIL-STD-461 EMI performance 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
Point of Contact
Kristi DePriest, Naval Air Systems Command (NAVAIR)
navair-sbir@us.navy.mil
Frequently Asked Questions
Why does the Navy need a new EMI filter design?
Increased use of wide bandgap power conversion for electrified aircraft systems introduces electromagnetic interference that can degrade avionics and mission systems if not properly filtered.
Why can't existing commercial nanocrystalline components solve this?
Commercial nanocrystalline cores are built either for high power at low frequency, like industrial drives, or low power at high frequency, like RF systems. Military aerospace applications need both high power and high frequency bandwidth together, along with more stringent EMI requirements than commercial electric vehicle parts are designed for.
What is the specific performance target?
Greater than 50 percent weight reduction compared to existing COTS CMVC filter and inductor components, while meeting EMI performance requirements in DO-160 and MIL-STD-461.
What kind of company background does NAVAIR expect for Phase I feasibility?
Demonstrated experience developing, manufacturing, and testing passive nanocrystalline magnetic core materials, along with the expertise to integrate those materials into EMI filter devices.
What TRL does Phase II need to reach?
TRL 5 through lab testing as a threshold requirement, with further testing to reach TRL 6 in a relevant end-use environment.
What does NAVAIR expect as a Phase II deliverable?
At least two CMVC EMI filter units demonstrating the targeted weight reduction and improved filter attenuation compared to existing COTS designs.
Is there a commercial market for this technology?
Yes. NAVAIR points to commercial aerospace as facing similarly demanding size, weight, power, cooling, and EMI/EMC requirements.
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
