Carbon Crunch
Overview
Buyer
Place of Performance
NAICS
PSC
Set Aside
Original Source
Timeline
Qualification Details
Fit reasons
- NAICS alignment with historical contract wins in similar service areas.
- Scope strongly matches core technical capabilities and delivery model.
Risks
- Past performance thresholds may require one additional teaming partner.
- Potential clarification needed on staffing minimums before bid/no-bid.
Next steps
Validate eligibility requirements, assign capture owner, and schedule partner outreach to confirm teaming strategy before submission planning.
Quick Summary
The Defense Advanced Research Projects Agency (DARPA) has issued a Solicitation for "Carbon Crunch," a program aimed at enabling scalable, fast, and agile production of hypersonic carbon-carbon (C-C) aeroshells. This initiative seeks to accelerate C-C aeroshell production through innovative manufacturing methods, demonstrating an end-to-end process from raw materials to near-net-shape densification. The goal is to achieve high quality, rapid production, and quick design-cycle turnaround, with technology intended for transition to hypersonic programs of record. This is an Other Transaction (OT) for Prototype Agreement, and Written Proposals are due April 10, 2026, at 4:00 p.m. ET.
Program Overview & Scope
The Carbon Crunch program focuses on developing and applying cutting-edge composite manufacturing methods that are inherently faster and more scalable for hypersonic aeroshells. Performers will be required to demonstrate an end-to-end manufacturing process, including preform layup to near-net-shape densification. The scope includes the aeroshell and potentially hot structure portions like leading edges and nosetips. DARPA is specifically not interested in novel thermal protection system materials, cooling technologies, parallelizing existing processes, processes reliant on touch labor, or final machining methods.
Key Requirements
- Develop a new integrated process for producing C-C aeroshells.
- Demonstrate high-rate production of C-C aeroshells.
- Demonstrate process agility for switching designs with minimal downtime.
- Assemble teams to demonstrate the entire aeroshell production process.
- Focus on reducing the time to densify C-C material and associated manual labor.
Contract Details
This opportunity is structured as an Other Transaction (OT) for Prototype Agreement under 10 U.S.C. § 4022. Multiple awards are anticipated. Cost sharing may be required, and various model OT agreements are provided (Attachments E1-E4) detailing fixed-flexible-based approaches with milestone payments. The estimated period of performance start is October 2026. Intellectual property and data rights provisions are detailed in the model OT agreements.
Eligibility & Security
Solutions are encouraged from all responsible sources, including large and small businesses, and nontraditional defense contractors. However, participation is limited to U.S. persons, with foreign nationals prohibited from accessing data/information. Proposers must comply with export control laws (ITAR, EAR) and protect sensitive/controlled data. Phase 1 will involve Controlled Unclassified Information (CUI), requiring appropriate safeguards. By Phase 2, performers must possess and maintain facility and personnel clearances for Secret collateral information.
Submission & Key Dates
- Proposers Day: February 3, 2026
- Last Day to Request CUI Addendum: February 12, 2026
- Abstracts Due: March 2, 2026, 4:00 p.m. ET (using Attachment B template)
- Written Proposals Due: April 10, 2026, 4:00 p.m. ET (using Attachment C template)
- Video Interview Sessions: April 20 - April 28, 2026 Evaluation criteria for abstracts and written proposals will be detailed in the CUI addendum. Required attachments include templates for abstracts, proposals, cost spreadsheets, data rights assertions, and milestone schedules.
Contact Information
For inquiries, contact the BAA Coordinator at DARPA-PS-26-15@darpa.mil.