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

Summary (Newest Update)

Background NASA's Marshall Space Flight Center (MSFC) is seeking to demonstrate large-scale manufacturing technology through thin-wall Laser Powder Directed Energy Deposition (DED). The goal of this contract is to fabricate subscale thin-wall nozzles and qualification samples using JBK-75, NASA HR-1, and specialty alloys in accordance with NASA and industry specifications. These samples are essential for metallography, mechanical, and thermophysical testing. Work Details The vendor shall complete the following tasks: 1. Fabricate witness test specimens for JBK-75 and NASA HR-1 using LP-DED, including round bars and harvest boxes. 2. Provide engineering support for LP-DED to complete build samples with a wall thickness of approximately 1 mm. 3. Prepare build plates for sample builds. 4. Review final models and refine the build approach for the RS-25 nozzle demonstrator. 5. Provide design inputs and develop toolpath strategies for NASA's confirmation. 6. Demonstrate LP-DED capability to print the aft end of an RS-25 nozzle exceeding 90” in height and 80” in diameter. 7. Ensure capability for 1 mm wall thickness at specified diameters. 8. Use JBK-75 Fe-Ni and NASA HR-1 Fe-Ni alloys as per requirements, allowing various usages of powder types. 9. Complete printing within 75 consecutive days or approximately 1170 hours of machine time, including engineering support, operator provision, consumables supply, a minimum build volume of 60” dia by 72”, an inert gas chamber to minimize oxidation, tool code generation, maintenance during builds, removal of parts from build plates, and other direct costs associated with consumables and components. The vendor shall also complete specific sample builds including two types of NASA HR-1 nozzles and witness specimens using JBK-75. Period of Performance 9 months from authority to proceed (ATP) Place of Performance Marshall Space Flight Center, Central Receiving, Bldg 4631, Huntsville, AL 35812 Bidder Requirements The vendor must have capabilities in laser powder directed energy deposition technology and experience with large-scale manufacturing processes similar to those required by NASA specifications. Incumbent Analysis (see Incumbents section for more detail) The opportunity appears to have a closely related prior contract with RPM Innovations under 80NSSC25PB548 for “Directed Energy Deposition JBK-75 Representative Process Build Samples” valued at $248,985 (07/28/25–01/28/26). The prior work focuses on LP-DED process builds using JBK-75, which aligns with the current requirement to fabricate thin-wall directed energy deposition samples and witness specimens using JBK-75 (and NASA HR-1) and to provide engineering support/toolpath development for nozzle demonstrator builds. This suggests the current effort may be a continuation or expansion of the earlier JBK-75 representative process build activities into additional thin-wall nozzle-related sample fabrication.