DON27BZ02-NV023 — Attritable Turbine for Low-Cost Attack Systems (ATLAS)

Design, develop, and prototype a low-cost, limited-life gas turbine engine producing 150-300 lbf of SLS thrust with an estimated engine life expectancy of 10-15 hours, leveraging advanced design and manufacturing techniques to significantly reduce part count, production lead time and scaling, and overall unit cost compared to traditionally manufactured engines in the same class.

The Department of War has an increasing need for affordable, reliable, and rapidly producible propulsion systems to support the proliferation of attritable Unmanned Aerial Systems (UAS), loitering munitions, and stand-off strike weapons. Current small turbofan and turbojet engines in the 150-300 pounds of thrust (lbf) class often rely on traditional aerospace material and manufacturing processes, resulting in high unit costs and long supply chain lead times. These factors are prohibitive for systems intended to be employed in mass or as expendable assets. This SBIR topic seeks innovative engineering and manufacturing approaches to design a turbofan engine that meets the thrust requirements while dramatically lowering cost per unit. Proposers should consider advanced design and manufacturing techniques to produce a low-cost engine that can leverage existing industrial base capacity to reduce risk to procurement supply chains. Key technologies and design features to consider are: Additive Manufacturing: Utilizing Powder Bed Fusion, Directed Energy Deposition and Direct Metal Laser Sintering (DMLS) to consolidate part count and simplify construction. Industrial (Non-Aerospace) Production Capacity: Leverage non-traditional aerospace manufacturing firms to reduce cost. Consider leveraging materials, casting and production techniques found in the automotive sector. Demonstrate a manufacturing pathway that enables rapid scaling and reduces supply chain bottlenecks. Short Life/Expendable Components: Utilizing non-traditional lubrication systems, bearings and electronic sub-components to limit cost. Optimized Materials: Utilize cost-effective materials suited for limited-life/single-use engine operations rather than traditional high-lifecycle aviation materials, where appropriate. Performance metrics of interest include specific fuel consumption (SFC), thrust-to-weight ratio, and operational reliability for mission durations typical of attritable UAS or cruise munitions. The engine will be fully operational utilizing Navy relevant fuels and demonstrate resilience to harsh maritime storage and launch conditions without significant performance degradation. The engine is expected to demonstrate functionality when subject to storage life of 6-12 months in Maritime environments and meet minimum required performance after exposure to shore-based and shipborne launch environments. Notional performance objectives for this SBIR topic are provided in the Tables below: Table 1: ATLAS engine notional operational envelop and performance objectives. Parameter Specification Electrical Power Generation [W] 500-1500 Thrust, SLS [lbf] 150-300 SFC [lbm/lbf/hr] < 1.5 Cruise Altitude [ft] 20k Table 2: ATLAS engine notional mass and dimensional properties objectives. Parameter Specification Approximate OML Diameter [in] < =10 Weight, Dry [lbm] 25-35 Length [in.] 14-24 Table 3: ATLAS engine notional storage & launch conditions. Parameter Specification Start Altitude Sea Level Start Method Air Impingement Storage Duration (Wooden Round) 6-12 months, Maritime Environment Launch & Assist Method Rail, Catapult, or Rocket Assist

Conduct a feasibility study and develop a conceptual design for a 150-300 lbf. turbofan engine. Identify the specific advanced design and manufacturing techniques to be utilized, optimizing the finished product for cost and producibility. Provide preliminary conceptual design modeling and simulation data (e.g., computational fluid dynamics, structural, and thermal analysis, cycle model) to validate conceptual design. Develop a comparative cost analysis demonstrating the projected unit cost and production time reductions versus traditional manufacturing baselines. Conduct a proof-of-concept demonstration and/or test campaign of the conceptual design, components, materials and manufacturing methods utilizing component level rig testing or lab testing where applicable. Monitor ongoing program risk and provide status updates throughout program progression. Deliver a Phase II development and testing plan.

Refine the conceptual design based on Government feedback and develop a detailed design for a fully functional prototype engine. Transition the Phase I conceptual design into fully functioning, physical hardware and demonstrate engine operation. Perform detailed component and system design based on Phase I deliverables. Manufacture detailed design test articles (produce physical engines) utilizing low-cost supply chain suppliers. Build and assemble fully functioning engine test articles. Demonstrate a cost-effective, reliable engine start system. Design and integrate a cost-effective engine control solution. Conduct a comprehensive test and validation program including completion of the required environmental tests to demonstrate engine performance, reliability and robustness of design. Perform a full endurance run to operational mission profile documenting performance. Refine mass production cost estimates including complete cost analysis and future cost projections. Identify manufacturing industrial base supply chain performers. Monitor ongoing program risk and provide status updates throughout program progression. Prepare a Phase III commercialization/transition plan.

Utilize lessons learned in the Phase II outcome to perform final detailed design and design for manufacture updates to increase Manufacturing Readiness Level (MRL). Update and continue test campaign for finalized engine design qualification/acceptance testing. Deliver a comprehensive engine performance test report summarizing performance against Navy-approved ATLAS criteria. Provide a detailed transition plan moving from Proof of Concept (POC) to Full Rate Production (FRP), Monitor ongoing program risk and provide status updates throughout program progression. Interface with airframe producer integrate engine into a host airframe for flight testing.