Family of Advanced Standard Batteries for Unmanned Systems - (FASTBAT-U)

Problem Statement:

As the need for reliable energy storage technologies grows, the Department of Defense (DoD) faces complex supply chain challenges. Establishing access to robust sources of National Defense Authorization Act (NDAA) Sec 154 and 1260H-compliant batteries, and supporting the growth of domestic battery manufacturing capacity, is of critical importance to the Defense industrial base. 

Desired Solution Attributes:

The DoD seeks fully commercialized, rechargeable battery cells that meet the performance needs of small unmanned aerial systems (sUAS) to include Group 1 and 2, with diverse mission requirements.

The DoD seeks proven (TRL 7+, MRL 7+) solutions with recurring commercial revenue, transparent materials sourcing, and at minimum, a manufacturing pilot line and roadmap to onshore, friendshore, or scale domestic/Allied production in the 10s-100s of MWh/yr, relative to your company’s business plan.

The DoD is interested in aligning the baseline performance profile with commercial markets, whether UAS, power tools, e-mobility, or other verticals. Where there is a delta with non-military customer requirements (e.g. energy density or peak power), please specify. 

Energy Cell 

• Gravimetric energy density: 290 Wh/kg
• Nominal (continuous) discharge rate: 2C
• Minimum pulse (30-60s) discharge rate: 5C
• Minimum charge rate: 1C
• Discharge temperature: Threshold (60% capacity retention at -20°C and operable to 55°C); Objective (60% capacity retention at -40°C and operable to 55°C)
• Charge temperature: Threshold (15°C to 45°C); Objective (0°C to 45°C)
• Cycle life (+1C/-3C): >300 cycles to 80% at 25°C
• Initial internal resistance (10s 1C pulse DCIR at 30% SOC, 25°C): Threshold (<10 mOhms); Objective (<8 mOhms)
• Temperature rise: <10°C cell surface temperature rise for continuous 2C discharge at 45°C ambient

Power Cell 

• Specific energy density: 180 Wh/kg 
• Minimum charge rate: 5C continuous, 10C pulse
• Minimum discharge rate: 20C continuous, 30C+ pulse
• Discharge temperature: -20°C to 90°C
• Charge temperature: 0°C to 90°C
• Cycle life: >50 cycles

Standardization

If submitting pouch cell solutions, propose standardization (e.g. dimensions, amperage, energy density, etc.) of no more than (2) cells based on your customers and markets best aligned to the sUAS performance baseline described above, and provide justification for your recommendations.

Safety

Describe relevant cell-level safety features (e.g. characteristics of cell chemistry, safety vent, non-flammable components, or other design features reducing thermal runaway occurrence when packaged). Submissions will provide proof of certification to UN38.3, IEC 62133, ANSI C18.5M or any other applicable industry certifications. 

Supply Chain

Contractor submissions should/shall detail the following:

• Active Electrode Materials sourcing by country of origin, percentage of Bill of Materials.
• Location of cell production facility/facilities specific to submitted cell solutions.
• Technology license(s) required to produce cells submitted for consideration, and the name(s)/location(s) of the licensors of that technology.

Manufacturing and Commercial Considerations

Contractor submissions should/shall detail the following:

• Production lines
  • Types of cells being produced
  • Level of automation, quality control, customizability of production line(s)
  • Throughput minimums to reach profitability, and maximum production capacity
• Financing
  • Capitalization 
  • Supplier agreements
  • Offtake agreements
• Localization/Scaling Plan
  • Onshoring or friend-shoring foreign production line to United States or its Allies with respect to batteries, and associated timeframe; or
  • Scaling US/Allied-based pilot line to automated production volume of 10-100 MWh/yr, and associated timeframe
• Recurring revenues 
  • Current demand and markets (military and civilian uses)
  • Pricing of cells in $/kWh at current and projected volumes
• Commercial risk assessment
  • Summary of cost drivers, e.g. for Bill of Materials, Manufacturing, Labor, or other costs.
  • How are these costs mitigated, e.g. with partners, increasing volumes, incorporating automation, etc.
  • Other commercial or regulatory risks, as applicable