Rapid Thermoplastic Patching Capability for Legacy Thermoset Airframe Sustainment

SBIR · Phase: BOTH · Topic DON27BZ02-NV018 · Solicitation 27.BZ

Current composite airframe repair methodologies rely on a combination of wet-layups, B-staged epoxy prepregs, and bonded pre-cured thermoset patches. While pre-cured patches are the standard for high-quality depot repairs due to their autoclave-consolidated strength and “inspectability”, they present significant operational and logistical limitations. All these traditional methods require secondary adhesive bonding (using paste or film adhesives) to attach the repair to the airframe. This secondary bond is the inherent weak link of the repair, demanding long thermal cure cycles (often 4 to 24 hours), strict environmental controls, and burdensome cold-storage logistics (freezers) for the B-staged resins and adhesives. Furthermore, these out-of-autoclave epoxy repairs often struggle to meet the high service temperature requirements of advanced tactical aircraft. This SBIR topic seeks to evolve the current pre-cured repair methodology by transitioning from secondary adhesive bonding to high-speed fusion welding. The objective is to develop the capability to use pre-consolidated, high-temperature thermoplastic patches (e.g., Carbon/PEEK, Carbon/PEKK) on legacy thermoset aircraft (epoxy/Bismaleimide [BMI]). By replacing the lengthy adhesive cure cycle with a rapid welding process, this technology aims to achieve flight-ready repairs in expeditionary and carrier-based environments in a fraction of the time. Because thermoplastics melt and thermosets do not, achieving a structural weld between these dissimilar materials is the primary barrier to fielding this capability. The Department of War seeks complete thermoplastic patching solutions that incorporate the requisite chemical or mechanical interfacial enablers—such as plasma surface activation, novel chemical tie-layers, or laser-ablated mechanical interlocking. These enablers must allow the thermoplastic patch to successfully fuse with a fully cured, legacy thermoset airframe using portable ultrasonic, resistance- or -induction welding equipment. The outcome must be a deployable repair process that eliminates cold-storage logistics, restores full structural integrity, meets high service temperature demands, and drastically reduces Aircraft on Ground (AOG) time.

SBIR/STTR 은 미국 중소기업만 지원할 수 있습니다(Small Business Act 법정 요건). • 계열사를 포함해 상시 종업원 500명 이하 • 미국 시민 또는 영주권자 1인 이상이 50%를 초과해 직접 소유·지배 • 미국 내 사업장을 두고 주로 미국 내에서 사업을 영위할 것 • 수행책임자(PI)의 주된 근무처가 신청 기업일 것 출처: https://www.sbir.gov/faq/eligibility-requirements

Primary country

🇺🇸 United States

Also eligible

None

Foreign companies

No

Local entity

Required

Location condition

미국 내 사업장을 두고 미국 시민·영주권자가 50%를 초과해 소유한 중소기업만 신청할 수 있습니다(법정 요건).

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Official URL

https://www.dodsbirsttr.mil/topics-app/

Application URL

https://www.dodsbirsttr.mil/topics-app/

Last fetched

2026.11.06

Human review

Not reviewed — check the official announcement

First seen

2026.11.06

Data status

Auto-collected, not reviewed

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