Low Cost / Rapidly Producible Booster Insulation Methods

The Missile Defense Agency is soliciting Phase I proposals for the development of affordable, scalable, and rapidly producible insulation technologies for solid rocket motors. The primary objective is to replace legacy filled polymer methods with novel materials and processing techniques that reduce production time and cost, specifically for polymer matrix composite and metallic motor cases. Key technical requirements include the development of reusable or low-cost consumable mandrels that ensure thrust misalignment of less than 1 degree, a 20-year storage life capable of withstanding temperatures as low as -40 degrees Celsius, and adequate propellant adhesion. Deliverables include sub-scale insulated cases, material characterization of thermal conductivity, and erosion rate characterization via sub-scale motor tests. This is a total Small Business Set-Aside under the SBIR/STTR mandate, requiring proposers to be registered in the System for Award Management and the SBA Company Registry. Awards are based on a best value trade-off analysis, prioritizing technical approach, investigator qualifications, and commercial potential over cost. The Phase I period of performance typically spans six to twelve months. Contractors must adhere to strict security and legal guidelines, including CMMC and DFARS 252.204-7012 for safeguarding covered defense information, and must disclose any organizational conflicts of interest. All proposals must be submitted as a single PDF via the DoW SBIR/STTR Innovation Portal.