DARPA Bets $12M on BAE Systems’ FAST Labs High-Temp Sensors

The U.S. Defense Advanced Research Projects Agency (DARPA) has awarded a $12 million contract to BAE Systems’ FAST Labs, its research and development division, to spearhead the development of next-generation pressure sensors under the High Operational Temperature Sensors (HOTS) program. This initiative, announced on December 9, 2024, seeks to improve existing sensor technology by enabling high-performance sensing in extreme thermal environments.

Addressing Limitations in Existing Sensor Technologies

Modern defense and industrial systems, such as hypersonic aircraft, missiles, jet engine turbines, and oil-and-gas platforms, often operate in extreme temperatures that challenge the limits of current sensor technologies. Existing sensors, constrained by materials like silicon-based transistors and traditional packaging, struggle to function beyond 225°C (437°F).

DARPA’s HOTS program aims to overcome these limitations by designing sensors that can operate reliably at up to 800°C (1,472°F). This advancement will significantly enhance the performance, safety, and operational longevity of critical systems that depend on accurate real-time data collection in harsh conditions.

Developing the Next-Generation Pressure Sensor

As part of the DARPA contract, FAST Labs will develop a cutting-edge pressure sensor module comprising an integrated transducer and signal-conditioning microelectronics. These components will be specifically engineered for high-bandwidth and high-dynamic-range performance, ensuring robust functionality in extreme heat.

Amrita Masurkar, technology development manager at FAST Labs, highlighted the potential impact of this technology:

“Advances in materials and processes now allow for high-bandwidth pressure sensors to perform in environments previously thought impossible. The HOTS program will enhance industrial process control, jet engine prognostics, and space exploration through real-time data collection.”

Broad Applications Across Defense and Industry

The sensors being developed under the HOTS program will have applications across various sectors:

• Hypersonic Aircraft and Missiles: Real-time monitoring of aerodynamic heating during flight to ensure operational safety and efficiency.
• Jet Engine Turbines: Advanced diagnostics to predict wear and optimize maintenance cycles.
• Space Exploration: Reliable sensor functionality in the extreme temperatures encountered during space missions.
• Oil-and-Gas Platforms: Enhanced monitoring of industrial processes in high-temperature operational zones.
• Automotive Systems: Improved performance and safety for vehicles exposed to intense heat.

Collaborative Development and Expertise

FAST Labs will conduct research and development at BAE Systems’ facilities in Nashua and Merrimack, New Hampshire, leveraging state-of-the-art resources. The program will also benefit from collaboration with prominent subcontractors and research partners:

• Penn State Applied Research Laboratory
• Purdue University
• Kampanics
• GE Aerospace’s Research Center

These partnerships will draw on expertise across materials science, microelectronics, and aerospace technology to ensure the successful realization of the HOTS program objectives.

Strategic Implications for Defense and Technology

This project highlights DARPA’s focus on advancing technologies essential for the U.S. Department of Defense and its allies. High-temperature sensors are crucial for systems like hypersonic weapons, which must perform reliably in extreme conditions.

For BAE Systems, the HOTS program reinforces its role in defense innovation, tackling challenges in materials and microelectronics to set new benchmarks for sensor performance in military and industrial applications.

The Future of High-Temperature Sensor Technology

High-temperature sensors like those being developed under DARPA’s HOTS program are critical for modern defense and industrial applications. By enabling real-time data collection in extreme conditions, these sensors improve operational safety, efficiency, and readiness.

DARPA’s partnership with BAE Systems and leading research institutions reflects the growing demand for innovative technologies to address the challenges of extreme environments. The HOTS program is set to advance capabilities for defense and industry while laying the groundwork for future technological breakthroughs.