Enabling a New Paradigm for Flexible, Point of Need Design and Manufacturing
March 18, 2024 | DARPAEstimated reading time: 1 minute
The Department of Defense (DOD) needs the flexibility to manufacture critical structures at the time and point of need using locally available materials. Yet current manufacturing approaches for forward production operate under the assumption that pristine raw materials will be readily available; furthermore, any change in material input would require costly redesign. This means that structure designs are reliant on fixed inputs to produce fixed outputs, hindering the flexibility required for forward production where raw materials and resources are limited.
DARPA’s new Rubble to Rockets (R2) program aims to overcome current limitations to manufacturing in supply chain-denied environments by developing production and design approaches that can accommodate widely variable input materials. Performers will focus on creating an inexpensive, flexible, and robust platform for the production and characterization of raw material for use in structural fabrication. They will then seek to apply that platform to adaptively update a sounding rocket’s structural design.
“Existing manufacturing approaches require stability. Building a framework that can enable the manufacture of structures out of anything, anywhere, and at many sizes would break the status quo for manufacturing in resource-contested environments,” said Hunter Martin, DARPA’s program manager for the R2 program. “We’re focusing on sounding rockets for proof of concept because they represent a single-use structure with multiple components and complex structural requirements, but anticipate broad applicability to a wide range of manufacturing use cases – from spare parts and infrastructure repair to system production.”
R2 will also look to leverage material informatics and innovative processing and manufacturing techniques to dramatically drive down the timeframes and scale needed for production.
DARPA hypothesizes that the analytical framework R2 aims to develop would allow for rapid upgrades to incorporate the growing number of new material developments and fabrication methods, thus significantly reducing adoption risk that traditionally can take decades to retire. Additionally, advances in material conversion and learnings from the program may open entirely new spaces for highly available material with a lower-risk supply chain and energy footprint.
DARPA will share further details on R2 in a forthcoming Program Solicitation (PS). An R2 Industry Day is scheduled for Mar. 18, 2024, to provide information to potential proposers on the objectives of the program.
Testimonial
"The I-Connect007 team is outstanding—kind, responsive, and a true marketing partner. Their design team created fresh, eye-catching ads, and their editorial support polished our content to let our brand shine. Thank you all! "
Sweeney Ng - CEE PCBSuggested Items
Jiva Leading the Charge Toward Sustainable Innovation
09/30/2025 | Marcy LaRont, PCB007 MagazineEnvironmental sustainability in business—product circularity—is a high priority these days. “Circularity,” the term meant to replace “recycling,” in its simplest definition, describes a full circle life for electronic products and all their elements. The result is re-use or a near-complete reintroduction of the base materials back into the supply chain, leaving very little left for waste. For what cannot be reused productively, the ultimate hope is to have better, less harmful means of disposal and/or materials that can seamlessly and harmlessly decompose and integrate back into the natural environment. That is where Jiva and Soluboard come in.
Space Forge Inc. and United Semiconductors LLC Partner to Develop the Supply Chain for Space-grown Semiconductor Materials
09/29/2025 | Space Forge Inc.Space Forge Inc., the advanced materials company revolutionizing semiconductor manufacturing in space, has announced the signing of a strategic Memorandum of Understanding (MoU) with United Semiconductors LLC, a leading specialist in bulk crystal growth of III-V semiconductor compounds. The agreement formalizes the ongoing collaborative efforts that started over a year ago, marking a significant step forward in strengthening the partnership between the two companies.
U.S. Critical Materials, GreenMet Join Forces in Strategic Alliance for Gallium and Critical Mineral Independence
09/29/2025 | PRNewswireUS Critical Materials Corp., a leading rare earth exploration and process technology company, is proud to announce a strategic advisory alliance with GreenMet, a Washington, D.C.-based firm specializing in critical minerals strategy and financing.
Connect the Dots: Evolution of PCB Manufacturing—Lamination
10/02/2025 | Matt Stevenson -- Column: Connect the DotsWhen I wrote The Printed Circuit Designer's Guide to...™ Designing for Reality, it was not a one-and-done effort. Technology is advancing rapidly. Designing for the reality of PCB manufacturing will continue to evolve. That’s why I encourage designers to stay on top of the tools and processes used during production, to ensure their designs capitalize on the capabilities of their manufacturing partner.
Nordson Electronics Solutions Enables Seamless Integration of Actnano PFAS-Free Coatings With Asymtek Select Coat Conformal Coating Systems
09/23/2025 | Nordson Electronics SolutionsNordson Electronics Solutions, a global leader in reliable electronics manufacturing technologies, announces full compatibility of its industry-leading ASYMTEK conformal coating systems with actnano’s next-generation, PFAS-free materials.