Commercialization of Ultra-High Payload-to-Weight UAS Subsystems | SBIR

OUSD (R&E) critical technology area(s): Advanced Computing and Software, Advanced Materials, Applied Artificial Intelligence, Contested Logistics Technologies, Human-Machine Interfaces, Integrated Network Systems-of-Systems, Integrated Sensing and Cyber, Microelectronics, Quantum and Battlefield Information Dominance, Trusted AI and Autonomy

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.

Objective: The overarching objective is to mature and commercialize revolutionary Unmanned Aircraft System (UAS) subsystem designs capable of breaking the 4:1 payload-to-weight ratio. This topic aims to transition high-risk, high-reward prototype concepts, specifically, those demonstrating exceptional promise in recent heavy-lift prototype programs, into manufacturable, commercially viable solutions for military and industrial use.

Description: The current heavy-lift bottleneck limits most multirotor UAS payload-to-weight ratios to approximately 1:1. Recent events, such as the DARPA Lift Challenge, have demonstrated that at least a 4:1 ratio is achievable through aggressive weight minimization, advanced materials, and novel propulsion. This Direct to Phase II (DP2) SBIR seeks to capitalize on the momentum of these highly innovative concepts.

There are two tracks (Track A and Track B) each with a unique set of end-of-period readiness tests and ultimate program objectives. Each proposal should contain a plan to accomplish all tasks, tests, and objectives for a single track. A proposing team may only submit one proposal per track. Note that in accordance with Sec 4(b)(5) of the Small Business Administration’s SBIR & STTR Policy Directive, no firm can be selected for more than one Phase II award on a given topic. Proposals must align with one of the following two tracks:

• Track A: Revolutionary Aerodynamic Design: Focuses on ultra-lightweight structures, novel airframe/rotor configurations, and architectures that enable high-capacity lift, alongside the integration of essential commercialization subcomponents (communications, autonomy, safety, and transportability) and the initiation of certification pathways.
• Track B: Revolutionary Powertrain Design: Focuses on transitioning high-efficiency, high-power-density propulsion systems into mass-produced, certified modules ready for integration into any platform.

A successful proposal will not only outline a clear plan to meet the technical milestones but also demonstrate a credible path to commercialization. The program is designed to fund teams capable of delivering a market-ready subsystem, supported by a complete technical data package and a viable certification strategy, within a 24-month period or less. A successful proposal to Track A or Track B will outline key personnel to manage the overall effort and a ramp-up team to perform the end-of-period readiness test. The successful team will have expanded their capabilities to design, manufacture, test, and certify their subsystem at a commercially relevant scale.

Phase I

Since this is a DP2 topic ONLY, a successful proposal must already contain evidence of a working proof-of-concept technology. The success criteria for the proof-of-concept are the following:

• Provide empirical data, flight logs, or prototype testing results that prove the baseline concept’s ability to meet or exceed the 4:1 payload-to-weight threshold.
• Provide first order analysis to complement the design configuration and the empirical data. Initial analysis is not intended to perfectly match the empirical data but to highlight areas of certainty and margins of accuracy that may be addressed in Phase II.
• Note to Proposing Teams: Data from participation in the DARPA Lift Challenge (e.g., flight results, structural load testing, design data) or similar rigorous testing environments is considered ideal for fulfilling this requirement and is highly encouraged.

The above information should be presented in such a manner that it is evident that the proposer’s technology can be tailored to meet the criteria in Phase II.

Phase II

A successful proposal will address the overarching technical objectives with performer-defined metrics over the course of 24 months or less. The program is structured with Readiness Tests at Month 9 and Month 18, culminating in an Ultimate Program Demonstration at Month 24. Proposers will be expected to identify at least one deliverable per month to meet incremental technical milestones to sufficiently advance their technology to meet the requirements of the Readiness Tests and Ultimate Program Demonstration. Since each Readiness Test increases in technical difficulty, proposals should outline a work plan to technically advance the designs to meet the demonstration scenarios within the provided timelines.

Track A: Revolutionary Aerodynamic Design

• Track A: Month 9 Readiness Test: Performers will demonstrate the initial manufacturability and repeatability of their aerodynamic design.
  • Task 1: Provide initial analysis foundation that quantifies physics underlying the aerodynamic configuration which establishes the revolutionary aerodynamic design. This may be supported by first order aerodynamic performance analysis, weights and balance, and initial stability and control margins.
  • Task 2: Produce three (3) identical copies of the primary structural component (e.g., airframe, chassis, boom) using scalable low-cost manufacturing processes. A successful proposal will identify a future transition away from bespoke, hand-laid prototyping methods toward scalable processes (e.g., automated fiber placement, mold-based composites, or advanced additive manufacturing). A successful team will establish the initial low-cost tooling and successfully manufacture three identical airframes or booms that prove the design can be produced consistently at scale.
  • Test: Conduct component bench and load testing on all three copies to demonstrate structural capacity of at least 4:1 payload-to-weight ratio and show less than 10% variance in failure load between units. The test plan must be submitted to DARPA for review prior to Month 9. A successful team will submit a rigorous, standardized test plan on time. They will build appropriate test fixtures and systematically load all three structures to failure. Success is achieving at least the 4:1 payload-to-weight threshold while proving high manufacturing quality control (the <10% variance), showing that their scalable process yields predictable, reliable parts.
• Track A: Month 18 Readiness Test: Performers will demonstrate the integration of their manufacturable airframe into a complete, flight-capable, and commercially viable UAS.
  • Task 1: Provide higher order analysis by taking the results from the previous test to update the aerodynamic configuration. Higher order tools may be used to validate predicted aerodynamic performance analysis, weights and balance, and stability and control margins.
  • Task 2: Integrate the optimized airframe into a full UAS weighing no more than 1320 lbs (with weight in anticipation of FAA Part 108). This integration must now include the subcomponents required for commercial employment: communications links, autonomy modules, safety systems (e.g., emergency flight termination, sense-and-avoid), and design features ensuring practical transport/logistics. A successful proposal will outline a strict SWaP (Size, Weight, and Power) management plan. A successful team will seamlessly integrate communications, autonomy, and safety features without exceeding the 1320-lb weight limit.
  • Test: Perform an untethered flight demonstrating a stable hover with at least a 4:1 payload-to-weight ratio while actively utilizing the integrated communications and autonomy features. The test must include a minimum of 5 minutes of continuous power to validate structural integrity under sustained load. The test plan must be submitted to DARPA for review prior to Month 18. Success means the integrated autonomy and safety systems function flawlessly under maximum load, and the final deliverable proves to a third party that the system is not just a prototype, but a manufacturable, certifiable product ready for market entry.
• Track A: Month 24 Ultimate Program Demonstration: Performers will demonstrate a comprehensive commercialization, manufacturing, and certification package.
  • Task: Deliver a complete technical data package (TDP) including CAD models, manufacturing instructions, and a bill of materials. Additionally, performers must demonstrate the formal initiation of the certification process for both manufacturing standards (e.g., AS9100) and operational employment (e.g., FAA airworthiness, military flight release).
  • Objective: The TDP, commercialization report, and active certification roadmap must be sufficient for a third party to understand its compliance and market viability for both military and commercial applications.

Track B: Revolutionary Powertrain Design

• Track B: Month 9 Readiness Test: Performers will demonstrate the manufacturability and repeatability of their powertrain subsystem.
  • Task 1: Provide initial analysis foundation that quantifies the physics underlying the propulsion architecture which establishes the revolutionary powertrain design. This may be supported by first order power performance analysis, net ratios such as power to weight, fuel efficiencies, thermal, and structural load impacts.
  • Task 2: Produce three (3) identical, complete powertrain units (e.g., integrated motor, ESC, and power distribution modules) using mass-production-ready manufacturing processes, moving away from hand-wound or custom-machined one-offs. A successful proposal will detail how the team will move from hand-wound stators or custom-machined parts to mass-production techniques (e.g., automated winding, standardized casting/machining). A successful team will establish these supply chains and produce three complete, integrated modules (Motor, ESC, Power Distribution) that look and function like final commercial off-the-shelf (COTS) products.
  • Test: Conduct rigorous dynamometer and bench testing on all units to demonstrate its capability. Performance variance (power output, thermal limits, efficiency) between the three manufactured units must be less than 5%. The test plan must be submitted to DARPA for review prior to Month 9. Success means proving that a team’s mass-production method yields virtually identical performance across all three units (<5% variance), validating that any UAS integrator can rely on uniform power output.
• Track B: Month 18 Readiness Test: Performers will demonstrate system reliability, durability, and readiness for platform integration.
  • Task 1: Provide higher order analysis that validates the physics underlying the propulsion architecture which establishes the revolutionary powertrain design. Update results from the previous test with power performance analysis, vehicle integration weights, fuel efficiencies, thermal management, structural load impacts, and performance due to operations at different air densities and altitudes.
  • Task 2: Subject the mass-produced powertrain units to an accelerated life-cycle and environmental stress test. A successful proposal will identify specific MIL-STD-810 test procedures (e.g., vibration, temperature extremes, humidity). A successful team will subject their powertrains to these harsh conditions and analyze the wear. They will finalize a TDP optimized for high-volume manufacturing and deliver a comprehensive compliance matrix showing how the module meets FAA and DoD airworthiness standards.
  • Test: Complete a continuous operation test simulating the dynamic loads, ascents, descents, and hover segments of a representative heavy-lift use case. The system must operate without component failure, thermal runaway, or degradation, proving its durability for repeated commercial/military operations. The test plan must be submitted to DARPA for review prior to Month 18. A successful team will run the powertrain through an intensive endurance profile that mimics the rapid power spikes and sustained high-throttle states of a heavy-lift mission (e.g., lifting 4:1 payload-to-weight ratio, maneuvering, and descending). Success is surviving this profile without thermal failure or component degradation, proving the module is a reliable, plug-and-play solution ready for immediate integration by UAS manufacturers.
• Track B: Month 24 Ultimate Program Demonstration: Performers will demonstrate a comprehensive mass-production and certification package.
  • Task 1: Deliver a comprehensive final analysis package that includes aerodynamic, structural, mechanical, electrical, controls and avionics.
  • Task 2: Deliver a complete technical data package (TDP) tailored for mass production, alongside a comprehensive certification roadmap (e.g., mapping compliance to FAA airworthiness standards and relevant MIL-STDs such as MIL-STD-810 for environmental engineering).
  • Objective: The package must provide a clear, documented pathway for any UAS manufacturer to adopt and integrate the powertrain as a certified, plug-and-play, high-performance module.

Phase III dual use applications

Phase III will be oriented toward transition within the DoD/military and further commercialization of the technology. Successfully commercialized subsystems will have immediate dual-use applications.

• Military: Tactical resupply, autonomous ammunition/ration delivery in contested logistics environments, and rapid casualty evacuation/extraction systems.
• Commercial Industry: Delivery of heavy construction materials to high-rises, automated disaster response logistics, heavy-duty agricultural spraying, and commercial cargo transport.

References

[1] DARPA Lift Challenge website: https://www.darpa.mil/research/challenges/lift

Keywords

UAS; Heavy-Lift Drone; Payload-to-Weight Ratio; Electric Propulsion; Lightweight Structures; Composite Materials; Contested Logistics; Scalable Manufacturing; Airworthiness Certification; Autonomy Integration.

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