Adaptive Manufacturing and Integration at Scale (10^n)

Background and Problem Statement: The current domestic space supply chain, is oriented towards low-volume, exquisite production of bespoke components for highly specialized spacecraft. This model involves long lead times, high costs, and minimal bench stock. Suppliers are typically small and specialized entities that produce components in units of tens, not hundreds or thousands.

This legacy approach cannot meet current demand, which is driven by a dramatic increase in heavy lift launch capacity, cadence (trending towards a launch every day),  and the need for proliferated satellite architectures. The existing exquisite supply chain will not scale without significant government investment and is unlikely to achieve the production levels needed to support the warfighter in times of conflict.

In response, the Department of War (DoW) is seeking commercial solutions to address production rate and capacity challenges in the U.S. space supply chain. This initiative aims to leverage digital design, AI-enabled software, adaptive manufacturing, and agile testing to rapidly produce dual- use space systems on demand and at commercial scale. Developing responsive, scalable and affordable  space systems is critical for maintaining U.S. technological leadership in the space domain.

The Desired Solution and Key Objectives

The DoW seeks commercial solutions to prototype and demonstrate responsive and adaptive production methods (e.g., design for manufacturing (DFM), artificial intelligence (AI), 3D printing, computer numerical control (CNC), automated molding, software-defined manufacturing) with the goal of creating a resilient, adaptive, and agile domestic space supply chain capable of on-demand production at an unprecedented scale.

Key objectives include:

• Achieve economies of scale in the U.S. space supply chain 
• Disrupt DoW’s dependence on exquisite sources of parts requiring long lead times
• Demonstrate on-demand production rates of hundreds of units per month (10²/mo) to thousands per year (≥10³/yr).
• Team commercial suppliers, advanced manufacturers, and defense integrators to address critical supply chain shortfalls as appropriate.
• Accelerate the advancement of space manufacturing readiness level (MRL).
• Employ an agile Design-Build-Test and Validate/Qualify iterative process to retain technological relevance.

Participant Roles

We will form teaming arrangements from the down-selected companies to collectively meet the needs of this AOI through an iterative process of digital design, adaptive building, operational test, and independent qualification.

Companies applying should identify with one of the following roles:

• Defense Integrators: Defense contractors with a successful history of executing DoW contracts for system-level production units (e.g., spacecraft, aerospace systems).
• Adaptive Manufacturers: Established companies experienced in scaling design-to-production throughput, including smart factories and agile supply chains.
• Disruptive Innovators: Companies of any size that have developed disruptive technologies or manufacturing capabilities that enable economies of scale (e.g., unique software, robotics, AI algorithms).

Success will be measured by the DoW’s ability to demonstrate substantial economies of scale in the mass production and integration of critical space components and systems.

Mandatory Attributes: 

• Must have an established production capability (e.g. technology, process, or facility) to meet the specified production rates (10²/mo or 10³/yr).
• Must be able to collaborate digitally throughout all prototype phases.
• Must be agile and able to source components at the speed of relevance.
• Defense Integrators must be willing to team with selected commercial companies.

Desired Attributes for Compelling Solutions:

• Ready to produce key elements of flight-ready hardware within 3 months of the award.
• Designed for autonomous operation.
• Produced domestically or via friendly foreign supply chains.
• Responsive and cost-effective at production scale.
• Solutions should be commercially viable independent of this specific government use case.

Product/Capabilities Exemplars

There are known critical space manufacturing supply chain bottlenecks and these challenges range from Tier 1 Systems, Tier 2 Sub Systems, Tier 3 Assemblies, Tier 4 Components and Parts, or Tier 5 Hardware and Materials. Examples include, but are not limited to, propulsion tanks, power supplies, star trackers, thrusters, rad-hard electronics, batteries, modems, crypto, harnesses, and/or domestic commodities production for space applications. It is anticipated that defense integrators include discussion of Tier 1 and Tier 2 supply chain bottleneck solutions while adaptive manufacturers and disruptive innovators can highlight specific Tier 3, 4, and 5 products/capabilities they consider candidates for this CSO.  Capabilities that enable scaled production rates (10²/mo or 10³/yr) are an example.  

Opportunity for Follow-On Production (Direct Award)



Companies are advised that a Prototype Other Transaction (OT) agreement awarded from this solicitation may result in a direct award for a follow-on production contract without further competition. This is contingent upon the successful completion of the prototype project. The follow-on production contract could be significantly larger in magnitude than the prototype OT agreement and may be used by multiple organizations within the DoW. All prototype agreements will include the relevant language in accordance with 10 U.S.C. 4022(f) to allow for this possibility.