Optimally Packaged Assembly for Laser Systems (OPALS)

SBIR topic DAF27BZ01-NV002 (U.S. Department of Defense – Air Force), Phase I and II. Open to U.S. small businesses. Opens: October 28, 2026. Closes: November 25, 2026. The Air Force requires light weight, compactly packaged optical systems to perform critical beam control functions for airborne high energy laser systems. The purpose of this topic is not to develop new outer moldlines or turret designs for airborne systems but rather focus on optimizing the packaging and performance of the internal optical system required to perform the core beam control functions. A canonical layout of such system is available in Reference 1. The Government expects the designed beam control system will perform all functions laid out in the canonical design - or that any deviations are thoroughly understood and technically justified. Additionally, designs should prioritize ease of alignment and component replacement, potential for line replaceable units, beam path conditioning, and material free of shedding contaminants which could lead to foreign object damage. In order to achieve these objectives, the Government anticipates investigations into the following areas, although this list is informational and is intended to be neither proscriptive nor comprehensive:Ruggedized Optical Design and MaterialsRobust Packaging and Assembly TechniquesNovel Optical Architectures: Explore and develop innovative optical designs inherently tolerant to vibrations, shocks, and thermal gradients.Advanced Materials Selection: Investigate and characterize advanced materials with superior thermo-mechanical properties. This includes exploring specialized glasses, ceramics, and composites for optical elements and mounting structures.Advanced Manufacturing and Assembly Processes: Investigate and implement advanced manufacturing techniques, such as additive manufacturing and precision micro-assembly, to fabricate intricate components and achieve high-precision alignment and bonding of optical…