Thin Wall Directed Energy Deposition JBK-75 and NASA HR-1 Nozzle and Representative

Statement of Work (SOW)

This Statement of Work (SOW) outlines the requirements for NASA's Marshall Space Flight Center (MSFC) to conduct a large-scale manufacturing technology demonstration using thin-wall Laser Powder Directed Energy Deposition (LP-DED). The effort aims to fabricate subscale thin-wall nozzles, material property testing process qualification samples, and process characterization samples using JBK-75 and NASA HR-1 alloys, as well as specialty alloys.

• Task 1: Witness Test Specimens Fabrication:

  • Fabricate witness test specimens to evaluate LP-DED processing of JBK-75 and NASA HR-1, using identical machine setup and parameters as the RS25 nozzle demonstrator.
  • Fabricate and provide engineering support for LP-DED to complete build samples with approximately 1 mm wall thickness and integral channels.
  • Prepare build plates and review/refine build approaches for JBK-75 thin-wall RS-25 nozzle demonstrator and representative build samples.
  • Provide design inputs and develop detailed toolpath strategies.
  • Demonstrate LP-DED capability using a large-scale machine platform for a RS-25 nozzle aft end (greater than 90" height and 80" diameter).
  • Utilize laser system for 1 mm wall thickness at specified diameters.
  • Materials: JBK-75 Fe-Ni and NASA HR-1 Fe-Ni alloys. Virgin powder, 1x, 2x, and 3x used powder are acceptable.
  • Print duration: within 75 consecutive days or approximately 1170 hours.
  • Includes engineering support, operator, consumables (Argon, nozzles, filters, utilities), build volume (min. 60” dia by 72"), and inert gas chamber.
  • Vendor to provide tool code, machine maintenance, and operators.
  • Required direct costs include consumables and necessary replacement components.
  • Engineering support includes tool path generation, inspections, troubleshooting, and reporting.
  • Parts to be removed from build plate as required.

• Sample Builds:

  • NASA HR-1 7K Thin-wall Nozzle, AFT (MER07362-013).
  • NASA HR-1 7K Thin-wall Nozzle, FWD (MER07361-013).
  • Witness Specimens (JBK-75, round bars, harvest boxes).
  • Target near net shape demo nozzle pieces and applicable coupons; quantities may vary.
  • JBK-75 witness samples to use identical parameters to the nozzle demonstrator and NASA-approved powder.
  • Runs to be consecutive on the same machine with acceptable breaks.
  • NASA to provide drawings, models, and dimensions.
  • Vendor to purchase JBK-75 rotary atomized powder (45-105 µm PSD) up to 1,000 pounds.

• Inspection & Reporting:

  • Vendor to complete final inspection of 7K nozzles using laser scanning.
  • Provide a report of scanning data from the 7K thin-wall nozzle.

• Period of Performance (POP): 9 months from authority to proceed (ATP).

• Place of Performance: Shipping to Marshall Space Flight Center, Central Receiving, Bldg 4631, Huntsville, AL 35812.

1. Witness coupons in the as-built condition from task 10.
2. Build report for witness coupon samples and nozzles, including any inspection reports.

• NASA will provide heat treatments and characterization/inspections.
• NASA will provide DED-sized powder (JBK-75).
• Witness coupons to be delivered in as-built condition without heat treatments.
• Vendor shall not utilize the dedicated 557 machine for other customers without NASA authorization. NASA will pay for machine time regardless of utilization.

Solicitation / RFP / RFQ

This notice indicates NASA/NSSC's intent to issue a sole source contract to RPM INNOVATIONS INC for Thin Wall Directed Energy Deposition JBK-75 and NASA HR-1 Nozzle and Representative. It has been determined that RPM INNOVATIONS INC is the sole provider. The government intends to acquire commercial items or services under FAR Part 12.

• Thin Wall Directed Energy Deposition JBK-75

• NASA HR-1 Nozzle and Representative

• Procuring Center: NASA/NSSC

• Performance Location: NASA/ Marshall Space Flight Center (MSFC)

• NAICS Code: 332117

• Interested organizations may submit capabilities and qualifications in writing.

• Deadline for submissions: Not later than 1:00 p.m. Central Standard Time on 6/12/2026.

• Submissions will be evaluated solely to determine if the procurement should be conducted on a competitive basis.

• Oral communications are not acceptable.

• This is currently intended as a sole source procurement.

• NASA FAR Supplement Clause 1852.215-84, Ombudsman, is applicable. Information on the Center Ombudsman can be found at the provided link.

• Primary Point of Contact: Cara Craft (cara.s.craft@nasa.gov)