· pdf filecontents introduction ..... iii air systems

ContentsINTRODUCTION .......................................................................................................... iiiAIR SYSTEMS Advanced Ceramic Matrix Composites (CMC) Manufacturing and Machining

Process Development ....................................................................................... 1Automation Of Rotorblade Erosion Coating Application .......................................... 2Guided Missile Antenna Manufacturing .................................................................... 3Kiowa Portable Alignment System ............................................................................ 4Manufacturing Technology for Advanced Nanocomposite Coatings ........................ 5GROUND SYSTEMSAdvanced Munitions Warhead Manufacturing Improvements .................................. 6Affordable ManTech for Structure and Armor ........................................................... 7Affordable Protection from Objective Threats ........................................................... 8Cannon Life Extension Program ............................................................................... 9Improved Manufacturing Technology (ManTech) for Insensitive Munitions (IM)

Nitrotriazolone (NTO) Process Optimization ....................................................10IMX-104 Manufacturing Process Optimization .........................................................11Multi-Purpose Warhead Manufacturing Improvements ............................................12Transparent SPINEL Armor Manufacturing Scale Up .............................................13ADVANCED MANUFACTURING INITIATIVESAccelerated and Adaptive, Army Fabrication Enterprise (A3FABE) .........................14Additive Manufacturing and Quick Tooling for Colorimetric Reconnaissance

Explosives Squad Screening (CRESS) Kits .....................................................15Net-Centric Model Based Enterprise (MBE) Data to Support Integrated

Weapon System Life Cycle ..............................................................................16SOLDIER SYSTEMS Enabling Hybridized Manufacturing Processes for Lightweight Body Armor ..........17Energy Efficient Expedient Shelters with Non-woven Composite

Insulation Liners ...............................................................................................18Lightweight, Affordable, High Performance Chemical/Biological Agent

Resistant Shelter Fabric for Joint Expeditionary Collective Protection ............19COMMAND, CONTROL AND COMMUNICATIONS SYSTEMSChip Scale Atomic Clock (CSAC) ............................................................................ 20Flexible Electronics and Displays .............................................................................21High Definition Multi-Band Focal Plane Arrays (HDMB FPAs) ............................... 22High Operating Temperature and Multi-Band Focal Plane Arrays .......................... 23Low Light Level Sensor ........................................................................................... 24Large Affordable Substrates ................................................................................... 25KEY POINTS OF CONTACT ........................................................................................ 27

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Army ManTech Program Overview

The Army Manufacturing Technology (ManTech) Program’s mission is to provide affordable and timely manufacturing solutions that address the highest priority needs of the Army. ManTech exists to reduce manufacturing affordability and producibility risks to enable transition of critical technologies to weapon systems platforms. The program accomplishes this through demonstration of effective, efficient and adaptable processes and encourages strong internal and external partnerships. Organization

The Deputy Assistant Secretary of the Army for Research and Technology (DASA R&T) has overall responsibility for the Army ManTech Program. Within this office, system portfolios directors provide oversight and coordination of ManTech consistent with Science and Technology (S&T) portfolio areas.

The U.S. Army Research, Development and Engineering Command (RDECOM), a subordinate command of the Army Materiel Command (AMC), has been further designated as the Army’s Man-Tech Program Manager. The Programs and Engineering (P&E) office within RDECOM performs this function and provides direction to the Army’s S&T Organizations. ManTech managers in these organi-zations are responsible for coordination with project managers for the execution of individual projects. This structure allows the Army to take advantage of system level technical expertise by maintaining close contact with both the acquisition managers and the corresponding technology managers. This approach seeks to maximize technology transition by maintaining a balanced portfolio aligned with S&T, Programs of Record and Department of the Army priorities.Investment Strategy

The investment strategy for the Army ManTech Program is to address relevant requirements to maximize technology transition. RDECOM engages with the Army S&T community, Program Exec-utive Officers (PEOs), Program Managers (PMs) and industry to strengthen ManTech products in support of Army priorities. Army ManTech is funded at approximately $60 million per year. Annual investment topics are identified by stakeholders and proposals addressing these topics are submitted through the S&T Organizations to RDECOM. ManTech efforts are vetted and prioritized through a series of reviews and criteria-based evaluations. The review process includes evaluations by the Joint Defense ManTech Panel (JDMTP), Army S&T stakeholders, relevant program offices and the Army ManTech Program Office. Evaluation criteria are centered on alignment with the prioritized investment areas, the strength of the projected transition, the estimated return on investment and the benefit to the Soldier. Final project selection is coordinated with RDECOM leadership and DASA (R&T).

Investments are strategically organized by the following portfolios:• AIR SYSTEMS - to include operations and support, survivability, rotors and flight controls, platform

technologies and unmanned systems• GROUND SYSTEMS - to include survivability, intelligent systems, unmanned systems,

vehicle power and mobility, precision munitions and deployable force protection • ADVANCED MANUFACTURING INITIATIVES - to address “above the shop floor” technologies

to include supply chain and model-based enterprise activities• SOLDIER SYSTEMS - to include Soldier loading, medical systems, and human dimensions• COMMAND, CONTROL AND COMMUNICATIONS SYSTEMS - to include communications,

intelligence and electronic warfare, sensors and mission command systems. The Army conducts semi-annual Internal Program Reviews (IPRs) for cost, schedule, program

metrics and implementation planning. Each project’s transition plan is routinely evaluated to see if projected metrics and transition milestones have been met. These IPRs and other supporting program documentation feed directly into the Army ManTech budget item justifications and success stories.

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Joint Defense Manufacturing Technology Panel (JDMTP) The Army actively participates in the Department of Defense (DoD) Joint Defense Manufactur-

ing Technology Panel (JDMTP) to coordinate ManTech efforts and maximize leveraged funding across the Services and the Defense Logistics Agency (DLA).

The JDMTP is composed of managers from the Army, Navy, Air Force and DLA ManTech Programs. This panel also includes an ex-officio representative from the Office of the Secretary of Defense (OSD). They define a taxonomy under which DoD components coordinate technical projects to optimize the investment of funds for manufacturing process development.

Army ManTech Website The Army ManTech website (www.armymantech.com) contains additional information about the

program to include technical success stories, related web-links and a contact button for attaining additional information.

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1Distribution Statement A: Approved for Public Release, Distribution Unlimited

UNCLASSIFIED

AIR

SYS

TEM

SAdvanced Ceramic Matrix Composites (CMC) Manufacturing and Machining Process Development

Improve the fuel efficiency and reduce the weight of the UH-60 Black Hawk and AH-64 Apache helicopters through the use of lighter weight, higher temperature capable, and more durable ceramic

matrix composite (CMC) turbine engine components.

OBJECTIVE / SOLUTION Helicopters are weight and price sensitive. Propulsion engine weight and fuel effi-

ciency impact mission duration and range. Application of advanced technologies will reduce weight and O&S costs. This project replaces conventional metallic engine component manufacturing processes with state of the art Ceramic Matrix Composite (CMC) processes. Application of new CMC technologies will significantly improve power-to-weight, specific fuel consumption (SFC), and reliability when compared to the current T-700 engine family. Fabrication, inspection and evaluation (destructive/non-destructive) of coupons and full-scale prototype hardware will validate the proj-ect’s success.

ACHIEVEMENTSProject results will contribute to meeting Force Operating Capabilities:

• MeetsTRADOCAirManeuverFOC-04-01ResponsiveandSustainableAviationSupport,04-02EffectiveAviationOperationsintheContemporaryEnvironment,Mounted/DismountedManeuver,04-05MountedVerticalManeuver,09-03AlternativePowerforPlatforms,ManeuverSustainmentIncreasedFuelEfficiency,FF7StrategicForceProtection,FF5SustainmentofModularForces,CF3LogisticsandMedicalinCounterinsurgency(COIN)andnon-contiguousbattlespace,CF4SoldierProtectioninCounterinsurgencyEnvironment

• Form/fit/functionreplacementdesignfornew/retrofitapplications• ProductionizedCMCmanufacturingprocesses,reducedO&Sandrecurringcosts,andimprovedrange(1%SFCreduction).

BENEFITS• CMC1stand2ndstageHighPressureTurbineShrouds(HPT)willbelighterandmoredurablethanmetallicHPTshrouds

• Improvedpower-to-weightmarginandSFCequatestoincreasedmissiondurationandloweroperationalcosts

• Providesform/fit/functionreplacementdesignfornew/retrofitapplications• Improvesdamagetoleranceandreducesrecurringcosts• ImprovedSpecificFuelConsumption(SCF)equatestosafetyduetoreducedfuelconvoys• ReducesCO²emissionsSTATUS

Completed and ongoing tasks include:• Requirementsdevelopmentanddetailedprogramplan(FY10)• Conceptualdesignandriskreductionplancomplete(FY10)• Evaluateadvancedslurrycompositions,systemdownselectionandrunprocesstrials(FY10-12).

POC: ArmyManTechManager,U.S.ArmyResearch,Development,andEngineeringCommand(RDECOM),AviationMissileResearch,DevelopmentandEngineeringCenter(AMRDEC),ManufacturingScience&TechnologyDivision,ATTN:RDMR-SEM,

5400FowlerRoad,RedstoneArsenal,AL35898-5000

STATUS (continued)• Stage1ToolingconceptscompleteandPurchaseOrdersissued(FY11),DownselectfinaltoolingandbuildStage2toolsfordemonstration(FY12)

• Evaluateprocesscapabilityformultipleshroudgeometries(FY10-11)

• Preliminarydesignofringshroudcomplete(FY10)

• EnvironmentalBarrierCoating(EBC)processapplication,stripandrepairevaluation(FY10-12)

• Investigateimprovedtowcoatingprocess(FY10).

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• UH-60BlackHawkandAH-64ApacheHelicopterfamily

• FuturerotorcraftengineprogramsforsystemssuchastheFutureVerticalLiftHelicopter

POTENTIAL COST AVOIDANCE• ReturnonInvestmentof10.3to1withacostbenefitof$82M

T-700Engine

EngineShroud

AH-64ApacheHelicopterUH-60BlackHawkHelicopter

2

UNCLASSIFIED

Distribution Statement A: Approved for Public Release, Distribution Unlimited



UH-60BlackHawkHelicopter

PaintBooth(RobotandCoatingDeliverySystem)

OBJECTIVE / SOLUTIONHelicopter main rotorblades are experiencing unacceptable removal rates due

to erosion from sand and moisture. The current UH-60 erosion protection manual coating process has the potential to exhibit out of tolerance coating thickness and can waste coating due to inefficient material transfer.

The automated coating system has been designed to accommodate a variety of coating technologies/materials and has the physical capabilities to coat blades for a variety of aviation platforms (AH-64 Apache, CH-47 Chinook, OH-58 Kiowa helicopters, etc.).

The current erosion protection material is dependent on uniformity of application of three separate materials (primer, basecoat, topcoat) within strict thickness toler-ances. Transfer efficiency that minimizes material waste is difficult given required applicator distance from coating source and geometry of coating coverage area. A multi-purpose solution requires interfaces for a variety of spray gun types, flexible fixturing, and an innovative coating delivery system. Consistent coating thickness is achieved by utilizing in situ system control feedback to monitor process parameters. The material source will be located at the best location to maximize effec-tive material delivery to rotorblades. ”State-of-the-Market” automated spray gun technology is being utilized to achieve precision spray patterns.

ACHIEVEMENTS• ThisAutomationprojectwillcontributetomeetingAirManeuverForceOperatingCapabilities(FOC)includingFOC-04-01(ResponsiveandSustainableAviationSupport-Tier1)andFOC-04-02(EffectiveAviationOperationsintheContemporaryOperatingEnvironment-Tier1)

• Selectedsystemcomponentsthatmaximizecoatingtransferefficiency• Systemcontrolstoinclude“in-situ”processmonitoring,defectdetection,andselfadjustment• Flexibleautomationsystemcomponentsthataccommodatevariouscoatingmaterialsandbladeconfigurations

• Rotorbladefixtureswithprecisionmountingpointsforautomatedprocessandmobilityformaterialhandling

• Increasedthroughput,reductionincoatingmaterialusage,andreducedcostduetoamoreefficientprocess

BENEFITS• Fleet-wideincreaseinoperationalreadinessfortheSoldierduetolongerlastingprotectionfromsandandrain

• Reductioninnumberofbladesthataredeemedunserviceable,resultinginAviationUnitsreplacingfewerblades

• IncreasedcapabilityforU.S.industrialbasetoprovideerosioncoatingprotectiononArmyaviationplatforms

STATUS• Programisinitsthird(final)yearoffunding(FY12)

• RoboticSystemIntegratorsourceselectioncompleted(FY11)

• SystemIntegratordesigned,developed,testedanddemon-stratedanautomatederosioncoatingprocess(FY12)

• AutomationsysteminstalledatcontractorfacilityandqualifiedtocoatUH-60A/Lmainrotorblades(FY12)

• ContinuetoleverageRotorDurabilityprogramforapplicationtofutureoferosioncoatingmateri-al/processes

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• UH-60/HH-60/SH-60“Hawk”Helicopterfamily

• OtherrotorcraftprogramssuchasArmyAH-64Apache,CH-47Chinook,UH-72LakotaandNavyCH-53SeaStallionandCH-46SeaKnightHelicoptersarebeingevaluated

• DevelopingautomationsoftwareprofileforUH-60MBlackHawkmainrotorbladesforimmediateproduction

POTENTIAL COST AVOIDANCE• ReturnonInvestmentof16.7to1withacostbenefitof$81.3M

Automation Of Rotorblade Erosion Coating Application Maximize rotorblade erosion coating uniformity and minimize material waste by automating the

application process. Provide a flexible solution for multiple aircraft platforms and multiple coatings.

AIR SYSTEM

S

RotorbladeDamagebyErosion

CurrentManualCoatingProcess


UNCLASSIFIED

AIR

SYS

TEM

S

OBJECTIVE / SOLUTIONThe objective of this project is to develop and demonstrate new methods

and processes to produce low cost missile borne antennas in high volume. Currently manufacturing issues exist in antenna manufacturing for radar guided missiles. While the antennas can be and have been manufactured in a laboratory environment it is clear that significant gains can be made in the reli-ability, producibility and cost of production through technology improvements. The benefits from this project are developing new processes that use the latest flexible circuit manufacturing techniques which increase their mechani-cal strength while at the same time retaining flexibility. New chemical etching and lay-up processes, reduction in wrap phases, and automated riveting and venting manufacturing will also be addressed.

ACHIEVEMENTSResults of this ManTech Project will include:

• Designandimplementnewprocessesusingthelatestflexiblecircuitmanufacturingtechniqueswhichincreasemechanicalstrengthwhileatthesametimeretainingflexibility

• Developnewchemicaletchingandlay-upprocesses,reductioninwrapphases,andautomatedrivetingandventingmanufacturingforuseinmanyantennaapplications.

BENEFITS• Increasesyieldratesby25%• Eliminatesautoclaveprocesses• Decreaseinlabortime,wastedmaterial,andlifecyclecosts(AverageUnitProductionCosts)• TransitiontoPMCruiseMissileDefenseSystems(CMDS)withEngineeringandManufacturingDevelopment(EMD)latein2014

STATUSProgram is in its second year of funding (FY12) with tasks including:

• Completeantennatestsforgovernmentownedminiaturein-finantenna• Injectionmoldantennasubstratedirectlyintomissilenosecones• Evaluatepolishingofmagnesiumfluorideresonators• Automatedalignmentforantennafrequencyenhancement.



Guided Missile Antenna ManufacturingDevelop and demonstrate cost effective, repeatable manufacturing technology and processes that can be utilized for conformal missile antennas, including transmit, receive, and datalink.

TraditionalMulti-layeredRivetedConformalAntenna

TwoPieceMoldedConformalAntenna Antenna

Mount

EQ-36CounterfireTargetAcquisitionRadar

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• IndirectFireProtectionCapabilityIncrement2(IFPC2)

• Radars• GroundVehiclesPOTENTIAL COST AVOIDANCE• ReturnonInvestmentof9.0to1withacostbenefitof$44.7M

Antenna

4

UNCLASSIFIED


Kiowa Portable Alignment System (KPAS)Enable field alignment of selected Kiowa Helicopter components without large non-portable,

alignment fixtures and reducing premature wear and cracks in structural components.

OBJECTIVE / SOLUTION The objective of this program is to develop

processes and techniques for precision assembly of components and structures to Kiowa and other aircraft platforms in order to provide equipment portability to support assembly requirements for Depot teams in field repair facilities. The technology approach is to utilize lightweight materials and high precision state-of-the-art laser measurement technology in an integrat-ed systems approach to assure maximum system flexibility. This approach will enable the transfer of these processes to other systems with similar requirements.

ACHIEVEMENTS• ProjectresultswillcontributetomeetingForceOperatingCapability(FOC)AirResponsiveandSustainableAviationSupport(FOC-04-01),Sustainability(FOC-09-01)andReadiness,Reliability,Maintainability,andcommonalityforSustainedOperationalTempo(FOC-09-04)

• Criticalcomponentsandalignmentprocedureshavebeenidentifiedandobtained,andresearchedandverified

BENEFITS• EnablefieldalignmentofselectedKiowahelicoptercomponentswithoutlargenon-portable,alignmentfixtures

• Reducedprematurewearandcracksinstructuralcomponents• ExtendedservicelifebetweenmaintenanceintervalsSTATUS• Programisinaoneyearfundedeffort• Requirementsdevelopment,conceptualdesign,andequipmentdeliveryhasbeencompleted• Kiowaaircrafthasbeenhands-onreviewedandmaintainerswereinterviewedontheaircraftandrepairprocedures

• Completedmeasurementandanalysisofoilcoolerdeck,transversebeams,tailrotorshaft,Station205,andCommonMissileWarningSystem-Electro-OpticMissileSensor(CMWSEOMS)

• Engine-to-Transmissionalignmentmoduleis95%complete.InitialproceduretestsuccessfullydoneatFortHood,TX

• ThealignmentmodulesforEngine-to-Transmission,CommonMissileWarningSystem(CMWS)-Electro-OpticMissileSensor(EOMS)andTailRotorDriveShaftare95%completedandhavebeendemonstratedontheOH-58DKiowaHelicopter

WEAPON SYSTEMS /



SECONDARY ITEMS IMPACTED• OH-58HelicopterFamily• Aircraftdynamiccomponentsrequir-ingaccuratealignment

POTENTIAL COST AVOIDANCE• ReturnonInvestmentof4to1withacostbenefitof$10M

OH-58KiowaHelicopter

CurrentDynamicAlignmentProcess

Station205,andCommonMissileWarningSystem-Electro-OpticMissileSensor(CMWSEOMS)

KPASOilCoolerDeck

KiowaPortableAlignmentSystems(KPAS)

AIR SYSTEM

S


UNCLASSIFIED

Manufacturing Technology for Advanced Nanocomposite CoatingsImprove manufacturing processes to efficiently implement advanced nanocrystalline diamond/

amorphous carbon coatings on performance-critical Army components.

OBJECTIVE / SOLUTIONThis ManTech effort will develop and demonstrate manufacturing improvements

that optimizes the manufacturing process for nanocrystalline diamond and amor-phous carbon SP3ECTM coatings. These coatings are produced using a room tem-perature Plasma Assisted Chemical Vapor Deposition (PACVD) process that allows the application of carbon thin films on a wide range of substrates achieving desired properties such as: improved optical transmission and durability for infrared devices; increased surface hardness; improved corrosion resistance; reduced friction; and increased wear performance for gears and sliding/wiping surfaces.

This project will mature the manufacturing processes required to affordably produce and implement advanced nanocrystalline diamond/amorphous carbon coatings on a variety of Army components.

ACHIEVEMENTSFirst year efforts include: rapid fixture machining equipment, design an alternate

etching chamber, in situ monitoring, data logging, vacuum chamber pumping and modifications to the existing coating systems to improve efficiency.

BENEFITS• Increasedcapacitythroughdesignandinstallationoflarge-scalemanufacturingflexibledepositioncells• Decreasednanocoatingprocessthroughputtimeinexistingandfuturecoatingsystemsthroughrapidfixture/toolingmachining,improvedcleaning/polishingandinsituprocessmonitoring

• Additionalefficienciesrealizedthroughreducedvacuumchamberpumpdowntime,datamanagementandadedicatedetch/reworkchamber

• Competitivepricingasaresultofincreasedcapacity,throughputandqualitycontrolSTATUS

The project is a four-year effort which began in FY11. • Thefirstyearoftheprojectfocusedonmodifyingthecurrentcoatingsystemsandprocessestoimproveefficiency.Thesemodificationsincludedreducingsystempumpingtimes,addinginsitumonitoringcapability,improveddatamanagement,alargerpowersupply,rapidfixtureprototypingcapability,partpreparationenhancements,andpreliminarydesignconceptsforalarger,moreefficientproductioncoatingdepositionchamber.

• Thesecondyearisworkingonprocessscale-up,reducingrework,enhancingin-housemachiningcapability,productiondatabasedevelopmentandfinalizingdesignforcoatingdepositionchamber.

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• AH-64ApacheTargetAcquisitionDesignationSight/PilotNightVisionSensor(TADS/PNVS),UH-60BlackHawkRotorHeadComponentApplicationsforCorrosionandWear,CH-47Chinookthreatdetectionsystem



WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED (continued)• PotentialapplicationsforOpticsdurabilityincludeTargetingOptics(Aviation,Missile,Tank).Corro-sionapplicationsincludedissim-ilarmetalspronetocorrosion(transmissions,actuators,landinggear,fasteners).Coatingimproveswearresistanceandreducesfriction;applicationsincludegearmesh,missilerails,gimbals,andenginecomponents.Frettinginterfaceswhenappliedtokine-maticmountingpointsunderhighloadstoimprovedurabilityandperformance


PlasmaAssistedChemicalVaporDeposition(PACVD)ChamberAH-64ApacheHelicopterPNVS

CoatedWindow

PlasmaCoatinginProcess

PNVSWindowonAH-64ApacheHelicopter

AIR

SYS

TEM

S

6

UNCLASSIFIED


OBJECTIVE / SOLUTIONDevelop novel manufacturing techniques to enable munition optimization of

weight, cost and performance. Focus areas include:• Molding of Insensitive Munition (IM) and fragment generating sleeves for

warheads• Multi-Explosive Formed Penetrators (M-EFP)• Embedded tungsten fragmenting components • Single increment, no-post machine explosive loading process for warhead bodies.ACHIEVEMENTS• SuccessfullymoldedwarheadbodieswithIMpolymerusingviableprocessforslowcook-offtesting• ManufacturedinitialEFPsforprocessprove-outandmaterialpropertytesting• Loadedlongwarheadbodieswithnovelpressingtechnique.AssemblieswillbeusedinballistictestingBENEFITS• Lowercostthroughreducednumberofmanufacturingprocesses• Improvedsafetybydecreasingtouchlaborduringmunitionmanufacture• MorereliablemunitionsusingfragmentingsleevesenablingwarheadstofragmentintoreliablesizedfragmentsandachieveIMrequirements

STATUS• InitialevaluationthroughwarheadperformancetestingofeachmanufacturingprocesscurrentlybeingconductedforIMsleeve,singleEFP,Embeddedfragmentcomponentandexplosivepressing

• ExpectedmanufacturingprocesstransitionintoMilitaryOperationsonUrbanTerrain(MOUT)startinginFY13

POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),ArmamentResearch,DevelopmentandEngineeringCenter(ARDEC),MunitionsEngineeringandTechnologyCenter(METC),ATTN:RDAR-MEM-L,PicatinnyArsenal,NJ07806-5000

Advanced Munitions Warhead Manufacturing ImprovementsDevelopment of manufacturing techniques on key components and assembly/loading process to

reduce advanced munition warhead manufacturing costs and enable munition optimization.

ShoulderFiredWeaponSystem

AdvancedMunitionsWarheadManufacturingProcessImprovements

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• MilitaryOperationsonUrbanTerrain(MOUT)ArmyTechnologyObjective(ATO),ShoulderFiredMunitions

• ExtendedAreaProtection&Survivability(EAPS)ATO

• 120mmAdvancedMulti-Purpose(AMP)

• ClusterMunitionReplacement(CMR)

• M1A2AbramsMainBattleTank• 60mmand81mmMortars• 40mmLowVelocity(LV)M433Improvements


GROUND

SYSTEMS

M1A2AbramsMainBattleTank


UNCLASSIFIED

Affordable ManTech for Structure and ArmorProvides design/planning tools and agile manufacturing technologies to expedite and enable high capacity

production for critically needed armor structures, composite armor assembly, and armor materials including ceramics, metallics and hybridized composites.

OBJECTIVE / SOLUTIONProvide agile, affordable armor system/materials manufacturing technologies

for advanced ground combat vehicle structure and armor solutions including:• Agile manufacturing technologies for affordable production of armor materials

and structures• Model Based Environment (MBE) to enable seamless annotation in coupling

computer-aided design and manufacturing planning/processes• Affordable production of advanced armor materials (e.g. silicon carbide,

bi-metallic laminates, metal matrix composites (MMC), high performance magnesium alloys, and tailored 3D woven composites)

• Friction-Stir Welding (FSW) and Gas Metal Arc Welded (GMAW) technologies for joining dissimilar materials and sub-assemblies

• Design and fabrication of a Ballistic Hull & Turret (BH&T) demonstrator to validate MBE and FSW technologies.

ACHIEVEMENTS• SuccessfullycompletedandshowcasedtheManTechBH&TDemonstratoratAUSAandDefenseManufacturingConferences;validatedMBEpracticesthroughcollaborativeeffortsofBAEandGDLSinajointdesignandmanufacturingventure;frictionstirweldingofthehull;andbuild-to-printarmormanufacturing

• Demonstratedsignificantweightreduction(>120lbs)ofaStrykerTroopRampbyusinghighperfor-mancemagnesiumalloy

• Validatedautomatedmanufacturingprocessesforsiliconcarbide(SiC)armortile.Demonstratedhighballisticperformanceofbothtitaniumandaluminummetalmatrixcomposite(MMC)encapsulatedstructuresandWE43magnesiumalloy

• Demonstratedcosteffectivemanufacturingofa3Dwoventhrough-thicknessreinforcedceramiccompositearmorpanel

BENEFITS• Providesenhanced,lighterweight,survivableplatformswiththeaffordablehigh-performancearmorneededfornextgenerationgroundcombatvehicles

• Reducescombatvehicledesign-to-productioncycletimeandcostofmanufacturingby25-40%

POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),ArmyResearchLaboratory(ARL),ATTN:RDRL-WMM-D,AberdeenProvingGround,MD21005-5069

STATUS• ConstructioncompleteonsecondgenerationSiChotpress;limitedproductionrunscontinuethrough1QFY13

• Completedvalidationproductionrunsfor3Dwovencompositepanelsandcryomilledaluminummatrixcomposites

• ConductingprocessvalidationproductionrunsforbothtitaniumandaluminumMMCencapsulatedceramictilemodules

• 3DwovencompositepanelsarenowconsideredtobeaqualifiedManTechmaterialoptionforuseinprimaryarmordesignapplica-tions

• Ceramicarmortileencapsulatedwithaluminum(Al),titanium(Ti),andsteelhasdemonstratedhighpotentialasanarmormaterial

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• Allpresentandfuturetacticalandgroundcombatvehiclesrequiringarmorandprotectionupgrades

• AdvancedarmormaterialsforIndividualSoldierProtection

POTENTIAL COST AVOIDANCE• ReturnonInvestmentof17.4to1withacostbenefitof$1.082B

ModelBasedEnvironment(MBE)BallisticHullandTurret

GROU

ND S

YSTE

MS

AffordableManTechforArmorMaterials

8

UNCLASSIFIED


OBJECTIVE / SOLUTIONProvide agile, affordable armor system/materials manufacturing technologies

for advanced ground combat vehicle structure and armor solutions including:• Development of forging/forming/joining and post processing technologies for

thick single piece underbody structures/kits fabricated using high strength alloys

• Manufacturing maturation and cost reduction of key armor materials: next generation armor alumina tiles, affordable encapsulated armor, automated tile insertion during armor fabrication, and 3D woven composite integration into high mass efficiency armors

• Cost effective processing and materials needed for next generation multi-threat armor components; automation/process efficiency for armor kit assembly.

ACHIEVEMENTSThis project began in FY12.

BENEFITSAffordable armor technologies to enhance vehicle and crew survivability:

• Formthicksinglepiecelowerhullorunderbody(U)armorkitsofnewhighperformancealloyswithlittletonoexposedweld/jointscapableofmeetingthenextgenerationunderbodyblastrequire-ments

• Producehighefficiencyarmorsandcomponentarmormaterialstomeetkineticenergyarmorrequirements

• Produceandefficientlyassemblemulti-functioncomponentsintonextgenerationmulti-threathybridarmors.

STATUS• ModifyingJacquardloomstoaccommodatefullsize3Dthrough-thickness-reinforcedcompositearmorconcepts

• Conductingcost/performance/manufacturabilityassessmentsofforgedorformedsinglepiecehullconcepts

• Conductinginitialmanufacturingcapabilityassessmentfordirectcastencapsulatedarmor• Procuringinitiallotofcandidatehighstrengthsteelforformabilityandweldingassessmentforunderbodykitmanufacturing

POC:ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM), ArmyResearchLaboratory(ARL),ATTN:RDRL-WMM-D,AberdeenProvingGround,MD21005-5069

Affordable Protection from Objective ThreatsProvides affordable manufacturing technologies to enable production for critically needed

underbody protection, ballistic and multi-threat armor assembly, and armor materials including ceramics, metallics, and hybridized composites.

EncapsulatedCeramicArmor

Enhanced3DThrough-Thickness-Reinforced(TTR)CompositeArmor

SinglePieceStructureandNewAlloysforEnhancedUnderbodyProtection

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• Allpresentandfuturetacticalandgroundcombatvehiclesrequiringarmorandprotectionupgrades

POTENTIAL COST AVOIDANCE• ReturnonInvestmentof12.2to1withacostbenefitof$2.4B

GROUND

SYSTEMS


UNCLASSIFIED

Cannon Life Extension ProgramDevelop both a reliable and consistent process for cladding the Inner Diameter (ID) of steel barrel forging

with Tantalum Tungsten alloy (Ta-10W), and the tooling/machining procedure to machine the Ta-10W lined barrels in affordable manner.

OBJECTIVE / SOLUTIONThe goal is to formulate a unique manufacturing method for affordable

chromium free manufacturing of cannon barrels. The Defense community faces significant challenges and deficiencies as the

next generation cannons are developed for our war fighting forces. The require-ment for increased muzzle velocity and penetration capability necessitates the development of propellants with increased energy and flame temperatures. These advanced propellants increase the wear and erosion of the barrel in all calibers of gun systems. There is also an environmental mandate from the Under Secretary of Defense to minimize the use of hexavalent chromium.

The technical challenges facing The Cannon Life Extension Program are achieving a consistent Inner Diameter (ID) on the Tantalum Tungsten alloy (Ta-10W) lined tube after the explosive bonding process, faster honing times, and machining rifling into the Ta-10W lined cannon barrels with crown-broach cutters instead of 2-point cutters (not an issue with large-caliber barrels).ACHIEVEMENTS• Two-pointriflingcuttershavebeendevelopedandsuccessfullydemonstratedtoworkonTa-10Wlinedcannonbarrels

• Successfullydemonstratedona40inchsectionofTa-10Wlinedtubeacrownbroachthathastheabilitytocutall18riflinggroovesatonce

• SuccessfullydemonstratedahoningprocedurethatisninetimesfasterthanthecurrentTa-10Whoningprocess

• Preliminarynondestructiveinspectionmethodsdeveloped• Inaside-by-sidecomparisontestwhilefiringstandardammunition,theTa-10Wlinedbarreldemon-strated3timesthelifeoverastandardchromelinedbarrel.With3timesthenumberofroundsfiredthroughit,itwasdeterminedthattheTa-10Wbarrelstillhad60%ofitsusablelifeleft.

• Inaside-by-sidecomparisontest,theTa-10Wlinedbarreldemonstrated50%increaseinlifeoverastandardchromelinedbarrelwhilefiringroundsloadedwithamoreenergeticpropellant

BENEFITS• Eliminatethehazardsassociatedwithhexavalentchromium• Developaminimumofa3timesextensionofthebarrellife• Providetheabilitytoutilizepropellantsthataremoreenergetic,leadingtoincreasedmuzzlevelocity

POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),ArmamentResearch, DevelopmentandEngineeringCenter(ARDEC),EnterpriseandSystemsIntegrationCenter(ESIC), ATTN:RDAR-MEE-P,PicatinnyArsenal,NJ07806-5000

STATUS• AstudywasconductedtoidentifythebesthoningstonestohoneTa-10Wonthecurrentmachines

• Newhoningprocessdevelopmentongoing

• CharacterizationoftheTa-10Wexplosivebondedtubesongoing.

• Preliminarycrownbroachdevelop-mentongoing

• Developmentofnon-destructiveinspectionmethodsongoing

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• Mediumcalibercannons(M24225mm,M68105mm)

• Technologywilltransfertolargeandsmallcaliberweaponssystems(M256120mm,M776155mm)

POTENTIAL COST AVOIDANCE• ReturnonInvestmentof28to1withacostbenefitof$285.5M

M2A1BradleyFightingVehicle

M777155mmHowitzer

ExplosiveBondingTechnology

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UNCLASSIFIED


OBJECTIVE / SOLUTIONOptimize process parameters for full scale production of nitrotriazolone (NTO)

re-crystallization. NTO is a key constituent in new insensitive munitions (IM) formulations.

The overall technical plan is to:• Increase NTO yield without affecting quality specifications • Through lab scale analytical analysis, determine what conditions will increase

yield in NTO re-crystallization• Implement these process conditions to full scale NTO re-crystallization

production by installing and integrating equipment necessary to achieve higher NTO yield.

ACHIEVEMENTS• ConductedbaselineresearchanalysisonNTOmanufacturing• ConductedDesignofExperiment(DOE)testonthermalprofileatre-crystallization• ResultsshowedcoolerprocessingtemperaturesincreasedNTOyield• VerifiedNTOcrystalstructureandmorphologyremainsintact• Demonstrateda10%NTOyieldincreaseinlab-scaleenvironmentwhichcantranslateintoasignificantincreaseinNTOyieldduringfullscaleproduction

• ContractAwardforImplementation• DesignReviewcompleted• FinalDesignPackagecompleted• Procuredlongleadequipmentitems• Constructionbeganmid-May2012• Equipmentinfrastructurebuilt• ProcessequipmentinstalledBENEFITS• AnoptimizedNTOprocessallowsanincreasedNTOyieldandimprovedcontrolstoobtainconsistentyields

• ProvidestheUSArmywithabetterenergetictocostratioperIMbenefit• IncreasedNTOyieldwilllowerNTOproductcostanddirectlylowerIMhighexplosiveproductcost• ProvidetheSoldieranIMcompliantproduct

Improved Manufacturing Technology (ManTech) for Insensitive Munitions (IM) Nitrotriazolone (NTO)

Process OptimizationProvides inherent cost benefits for scale-up of insensitive munitions (IM).

Nitrotriazolone(NTO)Powder

155mmM795HEIM(IMX-101) 60mmHEMortar

Nitrotriazolone(NTO)Crystals

STATUS• ThirdyearinManTechProgram• Implementingdesignonfull-scaleproduction

• Productionsitecloseddownfora6monthperiodstartingMay2012

• FacilityconstructionbeganMay2012

• Prove-outandcommissioningsetforendofFY12

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• InsensitiveEnergeticMunitions,IMX-101-usedin155mmM795and105mmM1HighExplosive(HE)InsensitiveMunitions(IM)

• InsensitiveEnergeticMunitions,IMX-104-usedin120mm,81mm,and60mmHighExplosive(HE)MortarFamily


POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),ArmamentResearch, DevelopmentandEngineeringCenter(ARDEC),EnterpriseandSystemsIntegrationCenter(ESIC),ATTN:RDAR-EIP, ArmamentSystemsIntegrationCenter,PicatinnyArsenal,NJ07806-5000

2,000GallonGlass-linedReactor

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UNCLASSIFIED

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MSIMX-104 Manufacturing Process Optimization

Provide inherent cost benefits for scale-up of IMX-104 manufacturing.

OBJECTIVE / SOLUTIONEstablish a capability to manufacture IMX-104, a Government-owned formu-

lation, with optimum process parameters to reduce the unit price while main-taining its insensitive munitions (IM) properties.

To accomplish this manufacturing process, this project will:• Examine/evaluate factors influencing product quality• Identify operating parameters that affect IM properties on a large scale

manufacturing process• Optimize critical operating parameters using Design of Experiment (DOE)• Prove out process• Confirm product quality and IM properties• Improve loading operations.ACHIEVEMENTS• Testplanhasbeenfinalized• LaboratoryscaleevaluationofrawingredientcharacteristicsonIMX-104hasbeencompleted• Design,fabricationandfeasibilitystudyof2,4-dinitroanisole(DNAN)pre-melterhasbeencom-pleted

• DNANpre-melterbuilttoanewdesignhasbeensuccessfullyprovedout• AnalternativemethodtomeasureviscosityisbeingdevelopedBENEFITS• InsensitiveMunitions(IM)compliantproductforSoldiers• Improvedmanufacturingefficiency• Betterunderstandingofoperatingconditionsonthequalityoffinalproduct• Potentialunitcostreductionbyasmuchas20%STATUS• Executionof10DOErunshasbeeninitiated• ProjectisbeingdevelopedutilizingtheBrookfieldViscosityMeasurementmethodWEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• IMX-104willsupporttheproductionofthe81mmHighExplosive(HE)mortar• IMX-104istheleadingcandidatetoreplaceCompositionBanditsequivalence,PAX-21andPAX-41astheHEfillinvariousmunitionsitems


POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommandRDECOM),ArmamentResearch,DevelopmentandEngineeringCenter(ARDEC),EnterpriseandSystemsIntegrationCenter(ESIC),ATTN:RDAR-EIP,ArmamentSystemsIntegrationCenter,PicatinnyArsenal,NJ07806-5000

IMX-104ManufacturingProcessFlowDiagram

81mmHighExplosive(HE)

Mortar

IMX-104ExplosiveFlakes

2,4-dinitroanisole(DNAN)Pre-Melter

12

UNCLASSIFIED


Multi-Purpose Warhead Manufacturing ImprovementsDevelop and demonstrate precise manufacturing methods and processes to provide affordable multi-purpose warheads needed to enable current and future tactical missile systems with the

capability of defeating Explosive Reactive Armor Protected Tanks, Soft Targets, Military Operations on Urban Terrain Targets and Personnel.

OBJECTIVE / SOLUTIONThis project will establish new processes to improve multi-purpose warhead

manufacturing on current and future missile systems. Currently there are innovative manufacturing processes which are increasing the capabilities and performance of warheads. However, not enough investment is being made in the development and maturation of these technologies focused on lowering the life cycle cost of warhead production.

The benefits from this project include reduction in variability, material loss, machining time, labor costs, and tool wear while increasing overall performance and reliability. These benefits will be achieved by utilizing near net shape preforms and heat treatment of assemblies.

Forging the liner into a near net shape preform will reduce material loss, forging steps, machining time, labor costs, and tool wear. The current bar process has many manufacturing steps that are labor intensive and lead to material waste. A post assembly heat treatment will also be utilized to improve multi-purpose warhead manufacturing. Current warhead assembly techniques induce stress in the explosive billet. A heat treatment process after warhead assembly will allow relief of internal stresses and ensure a bond between the liner and explosive. This process will reduce any variability introduced by the press and increase warhead reliability.

ACHIEVEMENTS• Forgednearnetshapebilletswith40%lessmaterialbyweightthanthecurrentmethod• Reducedforgingsteps,machiningtime,laborcosts,andtoolwear• ReducedporosityBENEFITS• Reducescycletimesandincreasesthroughputformulti-purposewarheadshapechargemanufacturing• Providessignificantreductionsinmanufacturingvariabilitytodecreasevariabilityinperformance• Decreasesinlabortime,wastedmaterial,andlifecyclecost(AverageUnitProductionCost)• PermitscurrentandfuturetacticalmissilesystemupgradessuchasJavelin,TOW,andotherArmysystems

• Reduceswarheadcostby15%

STATUSProgram is in last year of

funding (FY12) with tasks including:• ConductM-Chargeproducibilitystudies

• DevelopmanufacturingprocessesforM-Chargeliner

• DemonstrateM-Chargelinermanufacturingimprovements

• Testtoverifyresults• Transitionmanufacturingimprove-mentstoCloseCombatWeaponSystems(CCWS).

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• JavelinMissile• Tube-Launched,Optically-Tracked,Wire-GuidedMissile(TOW)

• Futuremulti-purposewarheadsystems


POC:ArmyManTechManager,U.S.ArmyResearch,Development,andEngineeringCommand(RDECOM),AviationMissileResearch,DevelopmentandEngineeringCenter(AMRDEC),ManufacturingScience&TechnologyDivision(MSTD),ATTN:RDMR-SEM,5400FowlerRoad,RedstoneArsenal,AL35898-5000

Multi-PurposeWarhead

NearNetShapePreform(left)vs.NormalPreform(right)

JavelinMissile

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UNCLASSIFIED

OBJECTIVE / SOLUTIONThe Army has compelling needs for affordable, lighter weight transparent ceramic

armors that provide improved ballistic protection for tactical vehicles and their crews. Glass-based transparent armors are thick and prohibitively heavy. SPINEL offers potential for lower weight, however, high manufacturing costs and limited manufac-turing capacity limits use in transparent armor applications. Recent ballistic experi-ments using advanced threats at Aberdeen Proving Ground have demonstrated the multi-hit performance of SPINEL at weights and thicknesses that are substantially less than deployed glass-based armors.

ACHIEVEMENTSThis project has demonstrated the interchangeability of SPINEL and aluminum

oxynitride (ALON) in transparent armor designs.

BENEFITSImproved multi-hit protection against current and emerging threats, including:

• Lightweighttransparentarmormanufacturedincurvedsizesupto22x32inches• Weightsavingsandthicknessreductionsof50-60%overcurrenttacticalvehiclewindows• CostpersquarefootoftransparentSPINELplatesreducedby20-50%• Superiorresistanceachievedforscratching,sanderosionandfractureduetorockstrikes• Improvedinfraredandopticproperties• Operationsandsupportcostsavingsviafuelsavings,increasedwindowservicelife,andreducedmaintenance.

STATUS• DemonstratedvolumemanufacturingandintegrationprocessesforlargestsizeplatesofSPINELandALON

• Increasedthemanufacturesizeofhot-pressedceramicplatesforDoDapplicationsfrom170in2• to700in2• DemonstratedmanufactureofcurvedSPINELplatesinsizesupto22x32inches• EvaluatingtheballisticperformanceofSPINELandALONfromthreeU.S.commercialmanufacturersWEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• SuccessfullyfabricatedballisticqualitySPINELplatesinsizestomeetArmytacticalvehiclerequirements

• Otherpotentialapplicationuses:-AdvancedTargetingForward-LookingInfrared(AT-FLIR)andSNIPERXRtargetingpodsforNavyandAirForceF/A-18classaircraft

-CeramicwindowsinNavyZumaltclassdestroyer(DDG-1000)

Transparent SPINEL Armor Manufacturing Scale Up Scale up manufacturing capabilities to produce large transparent armor for tactical vehicle windows

and plates for other specialized applications.

FineGrindingofaCurvedSPINELPlateDARPAUltraLightVehicle(ULV)withSPINELSideWindows

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED (continued)-Curvedsidewindowsinnon-tacticalvehicles

-U.S.militaryrotorcraftandairbornevehicles

-CriticalinfrastructureprotectionPOTENTIAL COST AVOIDANCE• ReturnonInvestmentof8.7to1withacostbenefitof$68M

POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM), ArmyResearchLaboratory(ARL),ATTN:RDRL-WMM-D,AberdeenProvingGround,MD21005-5069

SPINELPlate(19”x30”)ManufacturedbyARMORLINEisLargestTransparentCeramicPlate

ProducedCommercially.

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UNCLASSIFIED


Accelerated and Adaptive, Army Fabrication Enterprise (A3FABE)Achieve a totally digital and integrated product realization environment.

OBJECTIVE / SOLUTIONThe objective of the Accelerated Adaptive Army Innovation Fabrication Enter-

prise (A3FABE) program is to reduce the time to go from prototype design to a fully functional weapon system through the creation of the next generation of Army Prototype Integration Facility (PIF) organic capabilities. The Army’s next generation manufacturing enterprise will be able to utilize advanced model-based product data to achieve a digital, integrated product realization environment where designs and processes are optimized to rapidly and efficiently manufacture products.

ACHIEVEMENTS• DesignedandimplementedanArmy-RDECOMPrototypeIntegrationFacility(PIF)sourcingenvironmenttosupportrapidsoldiersneeds

• DeployedaMT-Connectenabledplatformforinspectionofprototypeproductionofprojectileswhichsignificantlydecreasedscrap-rateandproductionthroughput

• TheArmamentResearch,DevelopmentandEngineeringCenter(ARDEC)andBenetLabsarepilotinganintegratedsmartmachiningenvironmentwheremachiningdatacanbetrackedreal-timeinadash-boardportalforproductionmanagementandmanufacturingengineeringoperations

• ATechnologyTransitionAgreement(TTA)wassignedwithProjectManagerSoliderWeapons(PM-SW)BENEFITS• Time-to-fieldcycleisreducedby25%;soldierobtainsproductsfaster• Reductioninoverallproductioncostby20%• Increasedproductionthroughputby15%• Captureandreuseofmanufacturingknowledgeby50%STATUS

First year of the program ended in September 2012. Several RDECOM-wide Integrated Product Teams (IPTs) and small demonstrations have been established for an array of manufacturing process technologies (e.g., additive manufacturing, machining optimization, reverse engineering, product lifecycle management, and e-sourcing). Initial results of the technology maturity and business case look very promising.

M153CommonRemotelyOperated(CROWS)WeaponSystem

ADVANCED M

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WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• M153RemoteWeaponSystem,M2A1MachineGun,M777Howitzer,OH-58KiowaHelicopter

• RDECOM-FieldAssistanceinScienceandTechnology(FAST)Program

• Prototypedesignsandlegacyweaponsystems

POTENTIAL COST AVOIDANCE• ReturnonInvestmentof5:1to10:1perweaponsystemwithacostbenefitof$214.1M

POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),ArmamentResearch,DevelopmentandEngineeringCenter(ARDEC),MunitionsEngineeringandTechnologyCenter(METC),

ATTN:RDAR-MEM-L,PicatinnyArsenal,NJ07806-5000

AcceleratedAdaptiveArmyInnovationFabricationEnterprise(A3FABE)



UNCLASSIFIED

OBJECTIVE / SOLUTIONInjection molding is an inexpensive manufacturing technique for production of

large quantities of components but less efficient for small quantities. Expensive mold designs, mold production lead times, and slow mold setup times limit the use of these manufacturing processes for smaller quantities, especially when producing multiple sizes of similar components.

Still, in prototype fabrication and/or small production quantities, material property requirements necessitate injection molding processes. This project will use Additive Manufacturing (AM) in combination with Master Unit Die (MUD) technologies for molding plastic components for the CRESS kit.

ACHIEVEMENTSPreferred additive manufacturing processes and materials are actively being

procured. Additionally, the injection mold system frames have been identified and are being procured.

BENEFITSAdditive manufacturing and Master Unit Die (MUD) technologies can be combined

to shorten mold manufacturing and production setup times as well as reduced cost of the mold itself. The savings incurred through decreased mold costs and setup labor will be realized through a decrease per part cost, especially in low volume production runs.

Cost benefit occurs on the project due to multiple programs sharing the MUD set (all of which are/will be colorimetric based programs) and decrease cost to create mold tools yielding a 40% decrease in mold costs for each consecutive project.

STATUSCRESS kit mold tooling designs are approximately 50% complete. Material

sample testing to verify AM process output meets vendor material “design-to” specifi-cations is expected to begin shortly. As tooling data becomes available, mold tooling production with AM processes will begin.

Additive Manufacturing and Quick Tooling for Colorimetric Reconnaissance Explosives Squad Screening (CRESS) Kits

Uses Additive Manufacturing (AM) in combination with Master Unit Die (MUD) technologies to mold plastic components for the Colorimetric Reconnaissance Explosives Squad Screening (CRESS) kits.

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• ColorimetricReconnaissanceExplosivesSquadScreen(CRESS)kits


POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),EdgewoodChemicalandBiologicalCenter(ECBC),ATTN:AMSRD-ECB-PI-CP/KennedyE3330,5183BlackhawkRoad,AberdeenProvingGround,MD21010-5424

ADVA

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InjectionMoldingMachine CRESSBodyMold-2

CRESSKitModel(895-Mpd2Wampoules)

MoldCavitiesBuiltUsingAdditiveManufacturingMountedinAluminumFrame

16

UNCLASSIFIED


OBJECTIVE / SOLUTIONThis program seeks to develop, deploy and integrate Model Based Enterprise

(MBE) technologies and processes within the Army’s organic base to reduce manufacturing costs, risks and lead times for acquisition and sustainment.

Specific capabilities include:• Development and deployment of 3D product data tools such as fully-annotated

CAD models, digital work instructions to support manufacturing operations, 3D model validation, 3D based technical publications and 3D based engineering analysis tools

• Deployment of a Product Data Management system to support lifecycle opera-tions between engineering service agencies, product managers, depots and the defense manufacturing base

• Development of standard based MBE technologies to promote free dissemination and reuse of product data elements.

ACHIEVEMENTSTechnology Development• Developedandimplementedastandardschemaforcreatingfully-annotatedCADmodels• Matured3DPDFpublishingtechnologytoenablevisualizationoffully-annotatedmodelswithinthefreePDFdataformat

Technology Implementation• UtilizedaproductdatamanagementsystemtosupportproductionandfieldingofSparkIIMineRollerinterfacebracketsforProjectManagerCloseCombatSystems(PM-CCS)

• Developed3DfixturedesignsandanimatedmanufacturingworkinstructionsfortheMax-ProDashMineRollerInterfacebracketinsupportofPM-CCS

• Developed3D,animatedinstallationinstructionsfortheTOW-GPKtosupportfieldlevelinstallationinsupportofPM-MRAP

• Createda3DinteractiveelectronictechnicalmanualfortheM153-01installationprocedures• Transitionedthe3DmodelingschematoindustryandorganicpartnersBENEFITS• Reducedtrainingtimeforfieldlevelinstallation• Accesstorelevantproductdatatosupportoperations• ReductionsinMeanTimetoRepair(MTTR)• ImprovementsinpartsavailabilitySTATUS• A3D,interactiveserviceinformationcenterfortheRhino3.0systeminsupportofPM-CCSisbeingdeveloped

• Afully-annotated3DTDPfortheM2A1QuickChangeBarrelinsupportofProjectManagerSoldierWeapons(PM-SW)isbeingdeveloped

• A3DanimatedmanufacturingworkinstructionstosupportRESEToperationsatAnnistonArmyDepotfortheM2A1.50CalMachineGunisbeingdeveloped

Net-Centric Model Based Enterprise (MBE) Data to Support Integrated Weapon System Life Cycle

Provides selected Army activities, Program Managers (PMs), Arsenals, Depots, and Research, Development and Engineering Centers (RDECs) with the capability to utilize a Network Centric Manufacturing (NCM) enterprise

approach to create and transfer 3D product information using a Model Based Environment (MBE).

M-ATV

M2A1.50CaliberMachineGun

STATUS (continued)• AMBEMultiCAD/PLMEnvi-ronmenttoconductPLM-PLMvalidationofM2A1datasetsisbeingcreated

• Collaborationwithstandardorga-nizationstosolidifyandimplementMIL-STD-31000tosupport3Dproductdataisbeingcreated

• AtechnologytransitionagreementwithPM-ArmedReconnaissanceHelicopter(PM-ASH)tosupportactivitieswiththeOH-58Kiowahelicopterisunderway

• TechnologyandprocesstransferwithTARDECandAMRDECisunderway

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• Allcurrentandfuturetacticalandgroundcombatvehiclesrequiringreuseofengineeringdata

• AirsystemssuchastheCH-47ChinookandOH-58Kiowahelicopters

• OthersystemssuchastheM2A1,TOW-GPK,Rhino3.0,M153,M-ATV



ADVANCED M

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ComputerAidedDesign(CAD)ofCombinedState



UNCLASSIFIED

Enabling Hybridized Manufacturing Processes for Lightweight Body Armor

Provides the development, integration, and deployment of new, scalable manufacturing technologies to enable lighter body armor by exploiting advances in both multi-scale material and process technologies.

OBJECTIVE / SOLUTIONThe U.S. Army, and indeed the DoD-wide small arms body armor user commu-

nity, has requested that lighter versions of their highly successful ceramic-based armor be developed and fielded as soon as possible. The objective of this ManTech effort is to develop an integrated suite of manufacturing technologies based on recent material and process advances which can cumulatively deliver the same level of protection with a quantified reduction in total system weight.

ACHIEVEMENTS• DevelopednewprocessmethodsforB4Cceramics,whichincombinationwithnovelcompositebackingtechnologieshasdemonstratedacumulativeweightreductioninflatplate(non-curved)armorsystems

• ThroughpartnershipandparticipationwithManTechDoDandindustrialpartners,afirst-of-its-kindmachineforfullyautomatingtheassemblyofdissimilarmaterialsandarchitectureformatswasdesigned,built,andsuccessfullydemonstrated.ThesystemisknownasDissimilarMaterialsAssemblySystem(DMAS)andwillenablenovelassemblyandmaterials,fiberformats,andarchitectures

• NewbackingtechnologyandprocessmethodsdevelopedbytheArmyResearchLaboratory(ARL)andconfirmedbyManTechparticipantshasreduceddynamicbackfacedeformation,acriticalstepintheoverallbodyarmorweightreductionstrategy

BENEFITS• 20-30%touchlaborreductionbythedevelopmentandimplementationofautomatedandsemi-automatedmaterialhandlingandstackingtechnologies

• Abilitytoco-processceramicandpolymercompositehydrostaticallyatpressuresinexcessof5000psi• Semi-automationandintegratedbatchoperationsallowfor15-30%reductioninassemblycycletimeSTATUS• DissimilarMaterialsAssemblySystem(DMAS)installedatacontractor-neutralsitetoenabletechnologydemonstration,integration,andtransfertoU.S.bodyarmorindustrialbase

• On-goingsecondgenerationtestingofassembledbodyarmormaterialsintobothsub-scaleandfull-scaletestspecimensforcorrelationwithmaterialsandprocessparameters

• Continuingindependentconfirmationandoptimizationofbackingassemblymethodswithindustrialparticipantstoensureminimizationofdynamicbackfacedeformationassociatedwithsmallarmsprojectileimpact

‘Hard’BodyArmorProtectiveInsert

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WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• SmallArmsProtectiveInserts(SAPI)

• EnhancedSmallArmsProtectiveInserts(ESAPI)

• X-ThreatSmallArmsProtectiveInserts(XSAPI)

• DeltoidAuxiliaryProtectionSystem(DAPS)

• SidePlateProtectionSystems• Potentiallycommercialapplica-tionsincludelawenforcementandprivateprotectionpersonnelarmorsystems



DissimilarMaterialsAssemblyMachine(DMAS)

FromConcepttoBuildPhase

18

UNCLASSIFIED


SOLDIER

SYSTEMS

OBJECTIVE / SOLUTIONUntil recently, the current state-of-the-art insulation for military tents consist-

ed of lofted insulation liner kits. Lofted insulation kits soak up and hold water, thereby significantly decreasing thermal efficiency and increasing their already undesirable weight and pack size. These characteristics prevent most units from using the lofted insulation liners.

The goal of this effort is to provide an expedient insulation solution for soft-wall shelters providing significant energy savings and reducing the number of convoys necessary to deliver fuel for tent Environmental Control Units (ECU). Additionally, this insulation solution will be lightweight, easy to install and trans-port, and will enhance solider quality of life by reducing Soldier burden and increasing habitability.

Non-woven composite insulation liners have the potential to greatly reduce fuel requirements by helping to maintain habitable temperature conditions within Army deployed shelter systems. These liners use a flexible textile composite consisting of multiple functional layers that must be manufactured into a light-weight, durable, flame retardant laminate.

ACHIEVEMENTS• Evaluationofcoveringmaterialsandencapsulationmethodsfornon-wovencompositematerials• Laboratorytestingtoscreenandselectoptimalmaterialsandmanufacturemethods• Completionofsystem-levelairleakagetesting–resultsusedtoenhanceoveralllinerperformance• Completionofsystem-level,comparativeenergysavingstestingtodetermineeffectiveR-valuesandthermalbenefits

• Transitionpartner,ProductManager-ForceSustainmentSystem(PM-FSS),hasbeencloselyinvolvedinthedevelopmentandtestingofinsulationliners

BENEFITS• SignificantlyreduceslogisticalfuelburdenforexpeditionarybasecampswhileimprovingSoldierqualityoflife

• Reducessoldierexposuretoattackbylesseningthenumberoftripsrequiredforfuelresupply• OptimizesmanufacturingprocessesforlargescaleproductionSTATUS• Phase3oftheprogramiscurrentlyunderway.Duringthisphase,additionalprototypeswillbefabricatedutilizingthelessonslearnedfrompreviousphases.Repairandmaintenancemanualsforthelinersystemwillalsobedeveloped.

Energy Efficient Expedient Shelters with Non-woven Composite Insulation Liners

Develop an improved manufacturing process to increase the thermal performance, while decreasing the cost and weight, of non-woven composite insulation liners.

ThermalImageofDegradedPerformanceDuetoPrevious

ManufacturingProcess

Non-wovenCompositeInsulation

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• PMForceSustainmentSystem,ForceProvider

• UnitedStatesArmyMedicalMaterielDevelopmentActivity(USAMMDA),MedicalResearchandMaterielCommand(MRMC),FutureMedicalShelterSystem

POTENTIAL COST AVOIDANCE• ReturnonInvestmentof2.7to1withacostbenefitof$2.8Mwithinthefirst5years

POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),NatickSoldierResearch,DevelopmentandEngineeringCenter(NSRDEC),SheltersTechnologyEngineeringandFabricationDirectorate(STEFD),ATTN:RDNS-STF,KansasStreet,Natick,MA01760

InstalledNon-wovenCompositeInsulationLiner


UNCLASSIFIED

Lightweight, Affordable, High Performance Chemical/Biological Agent Resistant Shelter Fabric for

Joint Expeditionary Collective ProtectionProviding Chemical, Biological, Radiological and Nuclear (CBRN) protection at a

low mass, low cost in high volume for collective protection applications.

OBJECTIVE / SOLUTIONDevelop a process for reducing the weight of a Chemical, Biologi-

cal, Radiological and Nuclear (CBRN) laminate from 14oz/yd2 to 11oz/yd2. Based on successes with other laminate developments for Space and Missile Defense Command where mass is also critical, a Direct Roll process on the CBRN film substrate can be improved enough to reach the 11oz/yd2 target.

ACHIEVEMENTS• Successfullywovethinplyscrimwithlowtwistyarnstocreateathinsubstrate• Down-selectedfilmcandidatespassedMilStd282ChemicalWarfareAgenttesting• Implementedanarrow-widthslotdiecoatingheadintocurrentcoatinglineforcoatingdepositcontroltrial

• SuccessfullyranfirstmachinecoatingtrialwithnewslotdiecoatingheadBENEFITS• Reducedlogisticburden(weight,cube,cost)• Reducedsetuptime(Noneedforlinersystem)• TentsinfieldwillhaveinherentCBRNprotectionSTATUS

Contract was awarded in September 2011.

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• JointExpeditionaryCollectiveProtection• ChemicalBiologicalProtectiveShelter• LegacyCollectiveProtectionSheltersPOTENTIAL COST AVOIDANCE• ReturnonInvestmentof133.9to1withacostbenefitof$286.8M

POC:ArmyManTechManager,Research,DevelopmentandEngineeringCommand(RDECOM),NatickSoldierResearch,DevelopmentandEngineeringCenter(NSRDEC),SheltersTechnologyEngineeringandFabricationDirectorate(STEFD),ATTN:AMSRD-NSC-ST-F,KansasStreet,Natick,MA01760

CBRNSubstrateDirectRollProcess

Chemical/BiologicalProtectiveShelter

CBRNFilmLaminate

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UNCLASSIFIED


Chip Scale Atomic Clock (CSAC)Providing affordable precision timing for military communications systems.

OBJECTIVE / SOLUTIONGlobal Positioning Systems (GPS) are vulnerable to interference and unreliable

in urban areas and dense forests. A Chip Scale Atomic Clock (CSAC) will maintain network integrity, regardless of GPS availability. The goal of this project is to make CSAC affordable at less than $300/unit and producible with a desirable production rate of more than 20,000 units/year. Specific project objectives include design for manufacturability, yield enhancement, supply chain management, and transition to a disciplined volume manufacturing environment.

ACHIEVEMENTS• RedesignofCSACphysicspackageforbettermanufacturabilityandlowercostwascompleted• Completedcostanalysiswiththenewcomponentsusedinredesignedphysicspackageconfirmsthattheunitcostwouldbelessthan$300foravolumeorderof20,000units

• TheTechnologyTransitionAgreementwassignedwithProductDirector,Positioning,NavigationandTiming(PD-PNT)forpotentialtransitiontoPositioning,NavigationandTiming(PNT)FamilyofsystemswhichincludethePNTmobile,PNTHubandPNTEmbeddedproducts

BENEFITS• SignificantlyreducesacquisitioncostforJointserviceapplicationsrequiringprecisiontimingsubsystemsinSoldiercommunicationsystems

• Lowersunitcostandreducedprogramriskthroughtheestablishmentofmultiplesources• Movesfrommanualfabricationtoautomatedassembly• IncreasesunitvolumemanufacturingcapabilityfromMRL-4toMRL-8STATUS

Contractors are: • AdaptingMEMSmanufacturingprocessesandautomatingtheassemblyandtestprocessesforCSAC• RedesigningCSACincludingphysicspackage,electronics,andhousingformanufacturability,environ-mentalimmunity,andreliability

• Developingbatchprocesses,assemblyfixtures,andequipmentformanufacturingphysicspackagetoimproveyield,lowerlaborcosts,andreducerisksinreliability.

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• Command,Control,Communi-cations,Computers,Intelligence,SurveillanceandReconnaissance(C4ISR)Systemsrequiringpreci-siontimewithalowSize,Weight,Power,andCost(SWAP-C)

• GlobalPositioningSystem(GPS)UserEquipment

• SoldierCommunicationsEquipment

POTENTIAL COST AVOIDANCE• ReturnonInvestmentof42to1withacostbenefitof$978M

POC:ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),Communications-ElectronicsResearch,DevelopmentandEngineeringCenter(CERDEC),Command,PowerandIntegration(CP&I)Directorate,ATTN:RDER-CCB-PT,AberdeenProvingGround,MD21005

ChipScaleAtomicClock

M2A1BradleyFightingVehicle

LeadlessCeramicPackage

PrototypePhysicsPackage,PhotodiodeUpMountedinLowerHalfoftheVacuumPackage,

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OBJECTIVE / SOLUTIONEnable a pilot-line compatible process to deliver 1000 flexible displays/year,

the requirements of the Army transformation, and to improve the yield and reduce manufacturing costs. Reflective and emissive technologies implemented will be more rugged and efficient than current displays in use. Flexible display is the first implementation of large area high performance electronics and will be extended to additional electronics platforms including imaging devices, sensors, and energy harvesting. Ultimately the display and electronics can be combined into highly conformal systems and integrated onto soldier or vehicle platforms.

ACHIEVEMENTS• Processandtooldevelopmentworkhasenabledfabricationof4”diagonalfullcolorreflectiveultralowpowerdisplaysathightransistoryield(approaching100%)anddisplaypanelyield(75-80%)onplasticsubstrates

• Demonstratedhighperformancemetal-oxidetransistortechnologyonthe6”processdevelopmentlineanddevelopingprocessontheGENIIPilotline

• Integrationofthemetal-oxideThinFilmTransistor(TFT)backplaneswithfullcolororganiclightemittingdiodestodemonstratetheWorld’sLargestfullcolororganiclight-emittingdiode(OLED)onplasticsubstrate(7.4”diagonal)

• ContinuefabricationoffullcolorreflectiveflexibledisplaysontheGENIIpilotlinefortransitiontomilitaryintegratorpartners

• FlexibleDisplayandElectronicsCenter(FDEC)initiatedflexibleelectronicsdevelopmentofflexibledigitalradiographyleveragingthedisplaybackplanetechnology

• Continueindustrialdiscussionstotransitiontothebond-debondmanufacturingprocess• TheGENIIpilotmanufacturinglineisfullyinstalled,100%qualified,andhasdemonstratedfunctionalamorphoussiliconandmetaloxidetransistorsattheArmy’sFlexibleDisplayandElectronicsCenterinTempe,AZ.ThepilotlinenowincludesthefullcolororganiclightemittingdiodedisplayfabricationcapabilityandPINphotodiodesforthedigitalradiographytechnology.

BENEFITS• Lightweight,rugged,low-powerflexibledisplayswillenablesituationalawarenessinbothdaylightandatnighttime

• FlexibleelectronicswillenablewideareasensingwithinitialdemonstrationofflexibledigitalradiographyforArmyExplosiveOrdinanceDisposal(EOD)applications

• Flexibledisplaytechnologieswillenablesituationalawarenessfromtechnologynotcommerciallyavailablewithattributesthatcannotberealizedfromglass-baseddisplays

• $600/diagonalinchcostreductionperdisplayunit,from$800/diagonalinchto$200/diagonalinch• Possible5Xsavingsinlifecyclecosts

Flexible Electronics and DisplaysEstablish an integrated pilot line and processes to manufacture affordable flexible full-color active matrix

displays to improve yield and reduce manufacturing costs.

World’sLargestFlexibleOLEDonPolyethyleneNaphthalate

(PEN)

STATUS• ImprovedyieldandlowerdefectdisplaysintegratingOLEDsandmetaloxideTFTsfromtheGENIItoolset

• Centerhas30(anadditional3partnersfromFY09)industrialpartnersandthreeacademicpartners

• DemonstratedtheWorld’sLargestfullcolorOLEDonplasticwithmetaloxideTFTbackplanes,usingabond-debondprocess

• Continuetosupportlicenseagreementsandsupplychainindustrypartners

• Demonstratedimprovedcolorreflectivedisplaysintegratinganewtransistortechnology(metal-oxidethinfilmtransistors[MO-TFTs]).MO-TFTshavehigherperformanceandimprovedstabilitycomparedtoamorphoussiliconTFTs

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• PMForceSustainmentSystem,ForceProvider

• UnitedStatesArmyMedicalMaterielDevelopmentActivity(USAMMDA),MedicalResearchandMaterielCommand(MRMC),FutureMedicalShelterSystem


POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),U.S.ArmyResearchLaboratory(ARL),ATTN:RDRL-SEE-E,2800PowderMillRoad,Adelphi,MD20783-1197

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High Definition Multi-Band Focal Plane Arrays (HDMB FPAs)Develop low cost substrates for third generation focal planes that will significantly reduce focal plane costs and allow larger size focal plane arrays. This effort also will develop a small pixel format that will provide

high definition image quality and improve overall system performance.

OBJECTIVE / SOLUTIONDevelop large format, multi-band, multi-color Focal Plane Arrays (FPAs) at

comparable costs to single band Indium Antimonide (InSb) FPAs. This will enable affordable, high definition television (HDTV) infrared (IR) sensors for enhanced situational awareness/target search.ACHIEVEMENTS• OnsitereviewofpotentialFPAvendorscompleted• NightVisionandElectronicsSensorsDirectorate(NVESD)hascompletedinhousetestingofprospectivevendors

• MethodestablishedtoimproveoperabilitythroughgetteringfromSilicon(Si)substrates• Improvedbufferlayercrystallinity(<30arcsec)• FirstsetofbaselinearraysonGalliumArsenide(GaAs)substrates(640x48020micronpixel)showoperabilityat99%

• Firstspecificationcompliant720ParraycompletedBENEFITS• Reducedquantity,cost,size,weightandpowerofInfrared(IR)cameras• Providesincreasedfield-of-viewofdualband3rdGenerationFPAs• Provideshighdefinition,multi-bandsituationalawareness• Enablesanewwarfightingcapabilityinurbanenvironmentsusingwideareaelectro-optic(EO)persistentsurveillancefromhighaltitudeandfrommultiple,tacticalunmannedaerialvehicles(UAVs)operatingbelowtheclouds

STATUS• TwocontractsawardedinFY11• Latestwaferlothasyieldedspeccompliantarrays• ImagingdemonstrationhasbeencompletedWEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• TacticalUnmannedAerialVehicle(TUAV)Q2,Q3• LightweightLaserDesignatorRangefinder(LLDR)• AH-64ApacheHelicopter• CommonSensorPayload• JointStrikeFighter• WillbeinsertedintothenewCVASTprogramwhichincludesfourgroundvehiclesPOTENTIAL COST AVOIDANCE• ReturnonInvestmentof15.5to1withacostbenefitof$664M

POC:ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),Communications-ElectronicsResearch,DevelopmentandEngineeringCenter(CERDEC),NightVisionElectronicsSensorsDirectorate(NVESD),ATTN:RDER-NVS-STD,Ft.Belvoir,VA22060-5806

LightweightLaserDesignatorRangefinder(LLDR)

AH-64ApacheHelicopter HighDefinitionMulti-BandFocalPlaneArray(HDMB-FPA),theProducibilityAdjunctoftheVitalInfraredSensorTechnologyAccelerationProgram

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OBJECTIVE / SOLUTIONHigh performance infrared focal plane arrays (IR FPAs) are expensive and are

dominated by yield, growth and fabrication and not by die/wafer costs. The advances in making these FPAs point towards an opportunity for an investment that will result in significant cost avoidance.

Examples of anticipated advances are:• New detector structure whose manufacturing approach avoids defects associated

with passivation of the detector material• Detector material that uses the III-V material system enabling leverage of the III-V

material commercial industrial resulting in an increase in the yield and uniformity of these detectors

• FPAs that can operate at higher operating temperatures which significantly reduc-es the size, weight and power (SWAP) of cryogenic coolers, which enables use of compound, very large format FPAs in persistent surveillance applications.

ACHIEVEMENTS• Improvedflatnessandtotalthicknessvariation(20µto<5µ)ofGaSbsubstratesusingdiamondpointturning

• Improveddetectorlayeryield/performancesufficientlyfordownstreamprocessingof5MPixelBarrierHigh-Operating-TemperatureMid-Wavefocalplanearrays(HOTMWFPAs)(nBn)

BENEFITS• 1280x720highoperatingtemperatureandmulti-bandfocalplanearrays(HOTMBFPAs)providesearch,identifyandtrackmobiletargetsinallday/nightvisibilityandbattlefieldconditions

• HOTMBFPAscombinetoprovidereducedquantityandSWAP(3-5x)ofIRcamerasthrureducingFPAsizeandFPAcoolingrequirements

STATUSFuture/planned efforts include:

• Demonstrationof5MPixelFPAintestset• Demonstrationof8µpitchinterconnectssignificantlyreducingIRsystemSWAP• Demonstrationof4”GaSbsubstratethatisdoublesidedpolishedandmeetsflatnessrequirements• Improvedthick(6µ)layergrowthusingimprovedMBEshutterprocesses.

High Operating Temperature and Multi-Band Focal Plane ArraysReduce the cost of infrared focal plane arrays (IR FPAs) using III-V epitaxial material in order to make

large format, high operating temperature and multi-band/multi-color FPAs. This effort will provide affordable, 5000x5000 pixel format compound IR sensors for persistent surveillance and 1280x720 pixel format

IR sensors for enhanced situational awareness and target search.

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• GroundCombatVehicle• M1A2AbramsMainBattleTankModernizationProgram

• AH-64ApacheandArmedReconnaissanceHelicopter(PEOAviation)

• AdvancedCommonSensorPayload(ACSP)andFollow-onCSPProduction

• AirForceSpaceBasedInfraredSystem(SBIRS)Program/HighStareProgram

• PersistentSurveillanceprograms• LongEnduranceMultiIntelligenceVehicle


POC: ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),Communications-ElectronicsResearch,DevelopmentandEngineeringCenter(CERDEC),NightVisionElectronicsSensorsDirectorate(NVESD),ATTN:RDER-NVS-STD,Ft.Belvoir,VA22060-5806

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OBJECTIVE / SOLUTIONCurrent digital low light level sensors have insufficient resolution, are too expen-

sive, and fail to meet all performance requirements. This project will increase the manufacturing yield and lower the cost of these sensors, while concurrently increas-ing their performance for various multi-service applications (ground, surveillance, vehicle and aviation platforms) and accelerating their availability to the Soldier. The final product will be a fully mature production capability for a high resolution, digital, low light level sensor that can replace traditional image intensifier tubes in emerging systems. The effort also will result in a sufficient manufacturing capacity to meet initial Department of Defense (DoD) system level production requirements. A minimum of twelve cameras will be delivered throughout the effort in order to demonstrate that yield and performance improvements are being achieved.

ACHIEVEMENTSActual accomplishments include:

• Demonstratedproductionofmultiplesensorswithaphotoresponsethatishigherthantheprogram’sgoalnumber

• Costeffectivemoduleforproductionhasbeendefined.BENEFITS• Greaterthan75%reductioninthecostofthefirstfullycapabledigitallowlightlevelsensorandoptimizationofitsperformancecharacteristics

STATUSPlanned accomplishments through the 4th Qtr 2012 include:

• Continueactivationoptimizationinordertoincreasesensorphotoresponse• UpgradethecathodeandanodesealjoinertoincreaseyieldfortheISIE11sensor• Generateequipmentandfacilitizationplansforcomponentfeederlinestosupportprojectedproductionvolume.

Low Light Level SensorDigital low light level devices for emerging Soldier vision systems that provide the same or

better performance than current image intensifier tubes.

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• Armyfusednightsightprograms• Navypilotagenightvisiongoggleprograms

• Armyhelicopterpilotagenightvisiongoggleprograms

• OtherDepartmentofDefense(DoD)fusednightvisiongoggleefforts


POC:ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommand(RDECOM),Communications-ElectronicsResearch,DevelopmentandEngineeringCenter(CERDEC),NightVisionElectronicsSensorsDirectorate(NVESD),ATTN:RDER-NVS-STD,Ft.Belvoir,VA22060-5806

CurrentEnhancedNightVisionGoggle(ENVG)System

ISIE11SensorEnablesLowProfileSystems

FrontofUnfiredISIE11Sensor

RearofISIE11Sensor

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Demonstrate improved manufacturing processes for focal plane array detectors.

OBJECTIVE / SOLUTIONCurrent and future Army Infrared Focal Plane Arrays (IR FPAs) that use Mercury

Cadmium Telluride (HgCdTe) detectors are expensive, in large part due to the small size of the underlying Cadmium Zinc Telluride (CdZnTe) substrate. Additionally, the CdZnTe substrates are available through a single foreign source, putting future production at risk of disruption. Small substrates inherently drive up the cost of detectors as labor costs are essentially the same independent of substrate size. Developing the manufacturing technology (substrate polishing) to enable a domestic source of larger CdZnTe sub-strates would decrease the cost and risk of Army IR FPAs.

ACHIEVEMENTSThe selected domestic CdZnTe supplier is Raytheon Vision Systems (RVS). RVS,

working in conjunction with Teledyne Imaging Systems (TIS), are improving the polishing roughness and uniformity of the CdZnTe substrates required for molecular beam epitaxy (MBE) deposition of HgCdTe infrared detectors. The program demonstrated 6x6cm CdZnTe substrates and an improved polishing process for IR FPA defect reduction. HgCdTe infrared detector material demonstrated a factor of 3 total defect reduction.

BENEFITS• SignificantlyreducesacquisitionandtotalownershipcostsofIRFPAs• Costsavings–30%unitcostreduction• SignificantlyreducessupplierriskofmultipleDepartmentofDefense(DoD)IRFPAdevelopmentandpre-productionprogramsthroughestablishmentofdomesticsupplierofCdZnTesubstrates

• Providescombatoverwatch-theSoldiercanidentifythreatbeforetheycanevendetectpresence,SeeFirst/ActFirst

• Increasedsurvivability-theSoldiercanrapidlysearchwideareaswhileon-the-movewithimprovedstandoff

• Reducedcrewburden-Soldierfatigueisdecreasedthroughaidedsearchanddetectionforsurveillancetasksanddifficult/obscuredtargetswithshortertargetreportingtimelines

STATUS• Deliveredtwo3rdGenerationforwardlookinginfrared(FLIR)systemdevelopmentanddemonstration(SDD)FPAson6x6cmCdZnTesubstrates(ManufacturingReadinessLevel[MRL4]).Operabilityforbothmid-waveandlong-wavebandswasabove99%.

• ProducedmajoradvanceinCdZnTecrystalgrowthforIRsubstrates.• TransitioneddomesticCdZnTesubstratesto3rdGenIRIntegratedDewarCoolerAssembly(IDCA)ManTech(FY11)

• Increaseboulediameterandincreasewafersize,completebaselinelotsthrougharrayfabrication;completeprogramlot1;completeboulegrowthprocessimprovementandinitialsurfacefinish;workwithTitleIIIStrategicandSpaceCriticalTechnologyWorkingGrouptoestablishaninvestmentstrategytoaugmentcurrentManTechprogram(FY12)

• WillcompletebaselinelotsthroughFPAtest;completeProgramLot2andcompleteProgramLot3(FY13)

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED• CombatVehicleAdvancedSensorTechnology(FY13)

• MissileDefenseAgencySM3IIBProgram(FY12)

• AIDELongRangeAdvancedScoutSurveillanceSystem(LRAS3)(FY13)

• PMFLIR‘sNextGenFLIRB-KitEMDProgram(FY14)

• M1A2AbramsMainBattleTankModernizationProgram(FY14)

• AirForceSpaceBasedInfraredSystem(SBIRS)Program/HighStareProgram(FY14)

• PEOAviation:Apache(FY15)POTENTIAL COST AVOIDANCE• ReturnonInvestmentof13.3to1withacostbenefitof$147M

POC:ArmyManTechManager,U.S.ArmyResearch,DevelopmentandEngineeringCommandCommunications-ElectronicsResearch,DevelopmentandEngineeringCenter(CERDEC),NightVisionElectronicsSensorsDirectorate(NVESD),ATTN:RDER-NVS-STD,Ft.Belvoir,VA22060-5806

LongRangeAdvancedScoutSurveillanceSystem(LRAS3) LRAS3Image

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Key Points of Contact

HEADQUARTERS, U.S. ARMY RESEARCH, DEVELOPMENT AND ENGINEERING COMMAND (RDECOM) ManTech Program Manager,U.S. Army Research, Development and Engineering Command (RDECOM),ATTN: AMSRD-PE, 3071 Aberdeen Boulevard, Aberdeen Proving Ground, MD 21005

U.S. ARMY AVIATION MISSILE RESEARCH,DEVELOPMENT AND ENGINEERING CENTER (AMRDEC)AMRDEC ManTech ManagerU.S. Army Research, Development and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC),ATTN: RDMR-SEM, Rm. S240, 5400 Fowler Road,Redstone Arsenal, AL 35898-5270

U.S. ARMY RESEARCH LABORATORY (ARL)ARL ManTech Manager,U.S. Army Research, Development and Engineering Command (RDECOM), Army Research Laboratory (ARL),ATTN: RDRL-DPP 2800 Powder Mill Road, Adelphi, MD 20783-1197U.S. ARMY ARMAMENT RESEARCH DEVELOPMENT AND ENGINEERING CENTER (ARDEC)ARDEC ManTech Manager,U.S. Army Research, Development and Engineering Command (RDECOM), Armament Research, Development and Engineering Center (ARDEC), Tech Base/ManTech, Project Integration Office,ATTN: RDAR-EIP, Armament Systems Integration Center, Building 93, 2nd Floor,Picatinny Arsenal, NJ 07806-5000

U.S. ARMY COMMUNICATIONS- ELECTRONIC RESEARCH, DEVELOPMENT AND ENGINEERING CENTER (CERDEC)CERDEC ManTech Manager,U.S. Army Research, Development and Engineering Command (RDECOM), Communications-Electronic Research, Development and Engineering Center (CERDEC),ATTN: RDER-TSP, Building 6002,Aberdeen Proving Ground, MD 21005-5069

U.S. ARMY EDGEWOOD CHEMICAL AND BIOLOGICAL CENTER (ECBC)ECBC ManTech Program Manager,U.S. Army Research, Development and Engineering Command (RDECOM),Edgewood Chemical and Biological Center (ECBC)ATTN: AMSRD-ECB-PI-BP-CP/Kennedy E3330, 5183 Blackhawk Road, Aberdeen Proving Ground, MD 21010-5424

U.S. ARMY NATICK SOLDIER RESEARCH,DEVELOPMENT AND ENGINEERING CENTER (NSRDEC)NSRDEC ManTech Manager,U.S. Army Research, Development and Engineering Command (RDECOM), Natick Soldier Research, Development and Engineering Center (NSRDEC),ATTN: RDNS-BOO, Building 3, Kansas Street, Natick, MA 01760-5000

U.S. ARMY TANK AUTOMOTIVE RESEARCH, DEVELOPMENT AND ENGINEERING CENTER (TARDEC)TARDEC ManTech Manager,U.S. Army Research, Development and Engineering Command (RDECOM), Tank Automotive Research, Development and Engineering Center (TARDEC), ATTN: RDTA-EN, M/S 267,6501 East 11 Mile Road, Warren, MI 48397-5000

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