Rapid Response Prototyping and Manufacturing

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Rapid Response Prototyping and Manufacturing

• James Pope
• Title Project Team Leader
• Institution Prototype Integration Facility,
  AMRDEC
• Email pope-jd_at_rdec.redstone.army.mil
• Phone 256 876 - 7892

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Discipline Overview

• Objectives
• Rapid response to get technology into the hands
  of the soldier
• Scope
• Rapid prototyping
• Rapid limited production

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BOOST Choices
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Rapid Response Prototyping and Manufacturing
The army has a new emphasis in getting technology
into the hands of the warfighter faster. How can
we organize and operate to facilitate an
environment capable of rapid response?
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The Prototype Integration Facility
Mission To support Army Aviation, Missile, DoD,
Federal Agency, and technology activities in the
development, prototyping, test and qualification,
and production of systems, subsystems, and
components. To provide a rapid response
capability for solving technical problems and
providing quality product solutions to develop,
prototype, manufacture, integrate, and field war
fighting and other federal and homeland defense
capabilities. To manage, operate, and maintain a
Government-owned, Government operated
engineering, manufacturing, and integration
facility capable of executing the functions
required to meet mission requirements.
Dr. Larry O. Daniel Prototype Integration
Facility
Vision Provide Department of Defense (DoD)
Activities a Rapid Acquisition, Rapid Response,
and Best Value Alternative to Solve Technical
Problems and Provide Hardware Solutions to the
War fighter
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The Prototype Integration Facility

• Who We Are
• The Prototype and Integration Division,
  Engineering Directorate, AMRDEC
• Approximately 50 Government employees consisting
  primarily of
• Administration
• Engineering
• Over 100 contractor employees consisting
  primarily of
• Engineering
• Electrical and mechanical fabrication
• Integration
• Facilities
• Bldg 5405, Larry O. Daniel Prototype Integration
  Facility
• Administration
• Program management
• Engineering
• Bldg 4762 Platform integration, paint
• Bldg 5432 Circuit card plating line
• Bldg 5400 Electronic fabrication, assembly,
  test

• Program management
• Manufacturing support

• Program management support
• Administrative support

• Electronic and mechanical fabrication, assembly,
  test
• Platform integration

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The Prototype Integration Facility
Capabilities
Program Management Engineering Design and
analysis Circuit card design/layout Electronic
simulation, analysis and modeling Obsolescence
management Visualization Based Design
Laboratory Test Documentation

• Manufacturing
• CNC and manual machining
• Cable/wiring harness fabrication
• Circuit board fabrication and plating
• CCA assembly and test
• Electronic/mechanical assembly and test
• Rapid prototyping
• Stereolithography
• 3-D Printing
• Air and Ground Systems Platform Integration

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Rapid Response Prototyping and Manufacturing
Key Organizational Elements
Private Industry Establish effective customer
relations Remain focused on customer
requirements Establish an effective network of
subcontractors and suppliers Foster a team
approach among management, administration,
engineering, and manufacturing

• PIF Concept
• Provide Government-to-Government interface
• Remain customer and mission focused
• Develop effective teaming of Government,
  industry, and academia
• Foster a team approach among management,
  administration, engineering, and manufacturing

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Rapid Response Prototyping and Manufacturing
Key Operational Elements

• Manufacturability considered from the start of
  the design process.
• Multiple/alternate materials and parts
  identified.
• Existing tooling and processes utilized by the
  design.
• Thorough documentation reviews performed.
• Three dimensional solid parts and assemblies
  fabricated as early in the design process as
  possible.
• Close coordination between engineering,
  manufacturing, and purchasing.
• Strict documentation control.

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Rapid Response Project Examples
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TOW Bunker Buster
Provide IBCT ATGM LAV With Capability to Breach
Masonry Walls and Defeat Bunkers Until Mobile
Gun System Becomes Available

• Concept Modified TOW 2A Missile
• Scope
• Research and Development Phase
• Design a new Warhead Assembly and associated
  Missile modifications
• Execute test and qualification activities
  necessary to field the TOW Bunker Buster Missile
• Execute a Production Phase to modify 500 TOW 2A
  Missiles
• Team AMRDEC Propulsion Structures, PIF,
  AMRDEC System Simulation, AMRDEC Guidance
  Control, RTTC, AAD, Picatinny Arsenal, General
  Dynamics, Ensign-Bickford
• Results
• Program started in Dec 01
• Contract actions executed in 3 weeks to bring
  General Dynamics and Ensign-Bickford into the
  program
• Design, analysis, fabrication of test hardware,
  and test program (100 units) completed in 9
  months
• Fabrication and modification of 550 missiles
  completed in Apr 03

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Abandoned SA2 Rockets in Iraq
Provide Work Crew Tooling and Work Platforms to
Aid in De-tanking of SA2 Rockets in Iraq

• Concept New design
• Scope
• Design and fabricate a HMMVW mounted work
  platform
• Design and fabricate special tools for rocket
  disassembly
• Team MSIC, PIF, RTTC
• Results Design and fabricate tools and work
  platform in 30 days

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Blue Force Tracking Enhanced Information System
Communication and Tracking System That Provides
Situational Awareness and Command Control
to/from Air and Ground Platforms, Displays
Location for All Friendly Forces on an Electronic
Map in the Host Platform, Provides E-mail Text
Between Platforms

• Concept
• Utilize pre-existing fielded communications and
  tracking components
• Utilize unique racks, cabling, and mounting
  hardware
• Scope
• Design, test, and qualify Enhanced Information
  System
• Fabricate, assemble, test, and install systems
• Team PM TOC, AMRDEC AATD, PIF, AMRDEC AED,
  ATTC, IMMC OLRs
• Results
• Design started in Sep 02
• Fabrication started in Oct 02
• 96 systems installed by Dec 02 in Afghanistan and
  Kuwait
• 160 additional systems installed by Mar 03

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Mobile Tower System (MOTS)
Quickly Deployable, Highly Mobile Air Traffic
Control Tower for Remote Airfields

• Concept Develop Army system based on existing
  Air Force design
• Scope
• 12 month effort to design and qualify MOTS in
  Army ATC configuration
• Build 1 prototype system
• Integrate ARC 220 PRC 117s into tower
• Integrate COTS and GOTS software
• Integrate 10KW generators on trailers
• Perform qualification testing
• Environmental
• System performance (DT/OT)
• Develop preliminary Drawing package
• Team PIF, RTTC
• Results
• Prototype manufacture completed
• Qualification test in process

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Battle Damage Assessment Repair Kit
Kits With Parts and Tools to Temporarily Repair
Aircraft That Are Grounded Due to Enemy Fire or
Component Failure

• Concept Integrate kits using off-the-shelf
  tools and parts
• Scope
• Design and produce 11 deployable kits in 30 days
• Research technical data
• Develop eight (8) kit configurations
• Procure parts and materials
• Assemble kits
• Coordinate testing
• Ship kits directly to war effort
• Team PIF, AMRDEC AED, AATD, USAALS, DCD-Ft
  Rucker, ARL, AEC
• Results Kits produced and shipped on schedule

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Hellfire Mod K
Optimize Hellfire II Missile Lethality Against a
Broad Range of Targets

• Concept Non-intrusive modification to the
  Hellfire Warhead to increase fragment performance
• Scope
• Research and Development Phase
• Design a Fragmentation Sleeve for the Hellfire II
  Missile
• Conduct a test program of approximately 30
  warheads
• Execute qualification activities necessary to
  field the modified Hellfire II Missile
• Deploy 20 to 100 modification kits
• Team AMRDEC Propulsion Structures, PIF,
  AMRDEC System Simulation, RTTC, Air Force
• Results
• Design, test, fabrication, and in-country
  application of 20 modification kits completed in
  4 months
• Design modified to increase performance and 60
  additional modification kits completed
• Design modification to change material from mild
  steel to tantalum tested

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References

• www.redstone.army.mil/amrdec/pif/