Injection Molded Pressure Bubbles for Spacesuit Helmets

The contract solicitation 80NSSC26933381Q seeks qualified vendors to develop an injection mold and deliver twenty high-quality prototypes of a protective visor for future Exploration Extravehicular Mobility Unit (xEMU) spacesuit helmets, using injection molding technology. The work is performance-based at NASA’s Johnson Space Center in Houston, Texas, with all hardware required to be shipped to Building 420, Central Receiving. Key deliverables include not only the 20 visor prototypes but also comprehensive technical documentation: a mold design presentation detailing feasibility, wall thickness, draft, knit/weld lines, sink, warpage, ribs/bosses, tolerance feasibility, gate type and location, and venting strategy; a detailed process flow diagram spanning raw material receipt to shipment; and standard operating procedures and work instructions that define Nominal process parameters, including temperatures, pressures, cycle times, and alarm limits. Resin specifications including drying parameters, moisture content targets, shrink rates, and technical data sheets must also be provided. The visors must meet stringent optical, mechanical, and physical requirements: visible light transmission must be at least 82% across the 380–800 nm spectrum under photopic and scotopic conditions; they must withstand an impact of 125 pounds over a 4x4 inch area during intra-vehicular activity without catastrophic failure and survive a microgravity impact from a two-inch steel ball traveling at 1.4 feet per second while pressurized. The visor must conform precisely to outer dimensions in Figure 3 and include a retainer ring for circumferential retention. All hardware must be delivered as Class III with full documentation on a DD Form 250 listing contract number, part number, lot and serial numbers, nomenclature, shelf life, quantity, unit cost, and total cost. Each delivery must be accompanied by an Acceptance Data Package containing material certifications and inspection records, along with a Certificate of Compliance signed by a company official that includes the manufacturer’s details, lot and date codes, and quantities. The procurement is currently in a market research phase, requiring capability statements to be submitted via email to Cara Craft by 1:00 a.m. CST on June 4, 2026, to determine whether the effort will proceed competitively or as a sole source. Evaluation factors include Technical Capability, Past Performance, and Price, though specific weightings are not defined. The contract type is Firm