DON27TZ02-NV014 TITLE: Conformal Printed Antennas for Missile and Weapon Composite Airframes
OUSW (R&E) CRITICAL TECHNOLOGY AREA(S): Quantum and Battlefield Information Dominance (Q-BID)
COMPONENT TECHNOLOGY PRIORITY AREA(S): Integrated Network Systems-of-Systems;Integrated Sensing and Cyber;Microelectronics
PROJECTED CMMC LEVEL REQUIREMENT: Level 2 (Self)
OBJECTIVE: Develop and demonstrate conformal printed antennas for Navy missile, weapon, or aircraft composite airframes, addressing the coupled electromagnetic, structural, and environmental design problem inherent to printing radiating elements on small-diameter, high-curvature carbon-fiber substrates with integrated environmental protection. In particular, the Department is developing a number of low-cost counter-UAS effectors in the 40 mm, 70 mm, and 5" diameters. In order to keep costs down, one approach is to provide in-flight guidance updates until the seeker can detect the threat UAS. To reduce mass, we are seeking technology for printed or conformal antennas and circuitry.
DESCRIPTION: Rockets, missiles, aircraft, and tactical weapons are extremely weight constrained. Antennas for Global Positioning Systems (GPS) (including anti-jam), command and control, telemetry, datalink, and seeker functions must coexist with structural, thermal, environmental constraints on curved airframes. Conventional fabrication produces these antennas as discrete elements mounted on brackets inside separate radomes, connected to receivers via coaxial cables and connectors. This architecture imposes parasitic mass, parasitic volume, signal loss through cables and connectors, and long-term reliability degradation as connectors corrode and radomes delaminate over shipboard storage life.
Conformal printed antennas integrated directly onto composite airframe surfaces offer substantial advantages: reduced mass, reduced volume, eliminated cable and connector losses, and structural integration with the airframe itself. The technical challenge: printing radiating elements onto curved carbon-fiber substrates couples electromagnetic design with structural design, environmental protection, and the complex electrical interaction between printed conductors and the underlying conducting carbon-fiber substrate.
Multi-material printed electronics, particularly aerosol-jet and inkjet direct-write processes, have matured to where conductors, dielectrics, and substrates can be co-deposited into conformal structures with controlled electromagnetic properties. The unaddressed capability is the integrated design of printed antennas on airframe substrates, with environmental protection co-designed for operational survival.
The antennas shall be designed using direct-write printed electronics methods (aerosol-jet, inkjet, or comparable approaches) capable of multi-material co-deposition on curved composite substrates. Coating or environmental protection schemes shall be integrated into the design from the outset, with explicit treatment of electromagnetic transparency, loss, and detuning effects.
PHASE I: Define a concept for the target antenna application, including the conventional baseline being displaced and quantitative performance, cost, and lead-time targets. In conjunction with the Navy participants. identify a representative composite substrate and configuration with justification of diameter and curvature (preference for the 70 mm to 130 mm diameter range).Identify a coating or environmental protection scheme appropriate to the target application, with justification against the operational environment. Conduct joint research on the coupled electromagnetic-structural-environmental design problem, including initial design methodology, characterization of electromagnetic transparency and detuning effects of candidate coatings, and characterization of printed conductor performance on carbon-fiber composite substrates. Deliver a final report that includes technology base documentation, coating selection rationale and characterization, and baseline comparison; and a Phase II plan.
PHASE II: Develop the conformal printed antenna capability prototype and mature to TRL 6 on a representative configuration, including environmental qualification per relevant MIL-STDs on the coated configuration. Demonstrate fabrication and performance at relevant curvature, including documented print process control, inspection, yield characterization, and coating application. In conjunction with identified Navy transition program, demonstrate platform level integration and test, including (where feasible) captive carry, static fire, sled test, or flight demonstration. Document the path to qualified production, including supplier identification, equipment requirements, and cost and lead-time projections at production rate. Prepare a Phase III commercialization/transition plan.
PHASE III DUAL USE APPLICATIONS: Transition to the identified target Program of Record. Broader applications include Navy and Marine Corps strike weapons (PMA-242, PMA-201), air-to-air missiles (PMA-259), tactical rockets, small UAS (PMA-263), Marine ground-launched precision fires, and dismounted C4ISR antennas. Cross-service applications include Army PEO Missiles and Space, Air Force Armament Directorate, MDA, and Special Operations Command (SOCOM) antenna requirements on small-diameter platforms.
Commercial small UAS and advanced air mobility (conformal antennas on composite airframes); commercial space and small satellites (conformal antennas on composite stages and bus structures); automotive (conformal antennas for connected and autonomous vehicles); and consumer and industrial IoT. The qualification framework, including coating and protection, transfers to FAA-regulated aviation, commercial space, and other regulated markets where qualification of printed antennas on composites and other conductive substrates would provide weight and power advantages.
REFERENCES:
KEYWORDS: printed electronics; aerosol-jet printing; inkjet printing; direct-write deposition; multi-material printing; printed antennas; conformal antennas; carbon fiber composite; composite motor case; conformal coating; environmental protection; rain erosion; GP
TPOC 1: Greg Ruderman
gregory.a.ruderman.civ@us.navy.milTPOC 2: Timothy Ransom
timothy.c.ransom2.civ@us.navy.milTPOC3: Deborah Van Vechten
deborah.vanvechten.civ@us.navy.mil
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