DLA’s current battery portfolio, including the widely fielded BB-2590/U rechargeable battery (NSN: 6140-01-490-4316), relies heavily on lithium-ion chemistries with significant exposure to foreign (including Chinese-origin) supply chains. Section 154 of the FY2024 NDAA restricts DoD procurement from certain foreign sources beginning in October 2027, creating an urgent need for compliant alternatives. Beyond supply chain risk, lithium-based batteries present operational challenges including hazardous material classification for transport, thermal runaway risks, limited long-duration storage performance, and handling complexity in forward-deployed environments. DLA requires a non-lithium battery solution that can support BB-2590/U-class applications while improving: • Safety: Reduced or eliminated thermal runaway risk • Transportability: Less restrictive hazardous material classification and simplified logistics handling • Storage Readiness: Low self-discharge and long-duration storage (≥12–24 months) • Operational Performance: Reliable function across -30°C to +60°C environments • Durability: Resistance to shock, vibration, and field conditions • Supply Chain: Fully domestic or NDAA-compliant sourcing Solutions may not need to exceed lithium-ion performance in all areas but must demonstrate clear operational advantages in safety, logistics, or sustainment. Performance Targets: Proposed solutions should aim to meet or approach: • Energy Density: ≥150 Wh/kg (threshold), ≥200 Wh/kg (objective) • Cycle Life: ≥500 cycles to 80% capacity • Storage Life: ≥12 months with minimal degradation • Operating Temperature: -30°C to +60°C • Safety: No thermal runaway under standard abuse conditions • Transport: Reduced hazardous classification compared to Li-ion (if applicable) • MIL-STD environmental qualification testing covering temperature, vibration, and mechanical shock • Preliminary safety qualification aligned with MIL-PRF-32383/3 • Validated domestic bill of materials demonstrating NDAA-compliant manufacturability • Commercialization plan and domestic manufacturing roadmap with cost-per-unit projections at production volume Scope Phase I (6 months, up to $100K) Focus on cell-level feasibility and trade-space validation: • Demonstrate a non-lithium electrochemical system with initial performance data • Characterize: o Energy density (Wh/kg, Wh/L) o Cycle life projections o Voltage profile and discharge characteristics o Temperature performance • Conduct preliminary safety testing, including abuse tolerance • Perform storage/self-discharge testing • Provide: o Concept for integration into BB-2590/U-class form factor o Initial domestic supply chain assessment o Phase II development plan Phase II (18 months, up to $1M) Focus on prototype demonstration and transition readiness: • Develop a prototype battery module or pack aligned with BB-2590/U electrical requirements • Conduct: o Environmental testing (temperature, shock, vibration) o Extended cycle and storage validation o Safety characterization aligned with military battery standards • Deliver: o Prototype system demonstration o Validated domestic Bill of Materials o Manufacturing feasibility and cost model o Transition plan including pathway to qualification and DLA procurement
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