2015 DOD Maintenance Symposium


The National Center for Manufacturing Sciences (NCMS) will be showcasing many maintenance capabilities at Innovation Station, a Commercial Technologies for Maintenance Activities (CTMA). CTMA is a joint Department of Defense/NCMS effort promoting collaborative technology development, demonstration, and transition within DoD. Its objective is to ensure American troops and their equipment are ready to face any situation, with the most up-to-date and best-maintained platforms and tools available. With that in mind, the CTMA technologies that will be at this year’s event are as follows; Eclypse International, GE Digital, Siemens, SolAviTek, Sprectro Scientific, Stratasys and Universal Synaptics.

Eclypse technologies’ Electrical Component Analysis System (ECAS) provides an automated method to validate electrical paths quickly so that each path can be evaluated against similar paths immediately. The results are the ability to find “hard to locate” faults. Our products help to locate and eliminate root cause failures that many call “Gremlins” or “intermittent faults”. One of our many capabilities is that we can emulate operating level signal levels to include current and voltage. This is combined with an ability to test through relays and other complex assemblies while on aircraft to reduce disassembly level of the aircraft, saving even more time and retest.

GE Digital, through the CTMA program, has just launched a collaborative effort with NCMS and Naval Sea Systems Command to deliver predictive analytics and remote monitoring services in a 12 month proof of concept on six vessels (three Arleigh Burke Destroyers and three San Antonio Class LPDs). This pilot will establish the ability of GE Digital’s Predix Toolkit, particularly the SmartSignal analytics application, to deliver advanced early warning of impending equipment failures as well as sophisticated and actionable recommendations for resolving identified issues.

Siemens PLM Software: Integrated product development environments (IPDEs) are crucial to the financial performance of discrete manufacturing companies worldwide. Companies are heavily investing in resources and funding to capitalize on efficiencies gained through an optimized and robust IPDE. Product Lifecycle Management (PLM) tools are a critical catalyst in realizing the value of an IPDE. PLM systems can provide immediate impacts in the following areas to help organizations drive efficiency:

  • Accelerated product designs
  • Reduced engineering cycle times
  • Reduced scrap and improved manufacturing throughput
  • Lower production costs

Over the last ten years, manufacturers of instrumentation, industrial machinery, consumer electronics, medical, nuclear, aviation, packaged goods and other complex engineered products have discovered the benefits of PLM solutions and are adopting PLM software and best practices in increasing numbers. However DoD, with its huge inventory of legacy systems with isolated silos of technical data spanning a half century has lagged industry. Establishing a more seamless collaboration with industry will enable both entities to experience the benefits of PLM solutions across the lifecycle from design, production to sustainment.

SolAviTek is displaying a technology called Advanced Mobile Universal Tooling (AMUET). AMUET consists of a laptop/tablet controlling a network of test units that can be deployed at various locations on the vehicle under test via a family of generic e-socket interface connectors. Proprietary software allows easy programming to specific sub-system protocols. The system’s architecture follows common standardized processes that can easily be transferred to any vehicle platform, providing electricians with an array of automated test capabilities and vehicle historical information allowing rapid diagnosis of complete sub-systems over time.

On the manufacturing side, AMUET can be rapidly configured to learn electrical mapping and then use that information to provide the operator with all the information required to assemble and validate the configuration of electrical sub-systems. This is easily done on new wiring installations or modernization of legacy vehicles. The system also allows the skilled electrician to “reverse engineer” and evaluate existing configurations of legacy wiring of older sub-systems not being replaced or modernized.

On the maintenance side, AMUET can rapidly be configured to validate the integrity of critical sub-systems. It can be deployed to monitor the ageing fleet performance, using fleet baseline values and tracking tests results that identify open, shorts, degradation and intermittent faults degradations over time.

Spectro Scientific is displaying technology focused on supporting Condition Based Maintenance efforts.

Problem: Oil analysis in the field is not effective because assets are separated from oil analysis laboratory support. In many cases, oil analysis was waived during combat operations; when needed most.

In 10 minutes or less, the two most important questions are answered: “What is the condition of my equipment and, how long can I continue to operate?”
Solution: New analytical tools and diagnostic software in the hands of the maintainer in the field empowers them with immediate condition based assessment of the oil’s integrity and the mechanical condition of the asset.

Stratasys, through Direct Digital Manufacturing attacked conventional method of small batch processing of expensive and time consuming CNC machining.


Before adding direct digital manufacturing to its processes, the TDF used conventional manufacturing methods to make its products. Because most of their projects are either one-of-a-kind or very low volume, conventional methods become very costly.


The TDF employs four Stratasys FDM additive manufacturing systems to fabricate a wide majority of its training products. When it came time to design and manufacture an exact replica of an unmanned aerial vehicle (UAV) or “drone” for training repair technicians, they turned to their FDM systems and built a variety of durable, complex internal and external components to be used as the final production parts.

Stratasys is shaping our world. Our trusted 3D printing solutions widen the path of innovation, empowering leading manufacturers and groundbreaking designers, makers, thinkers and doers. By moving quickly from idea to solid object, our customers untangle complexity and uncover solutions with the speed and urgency our world demands.

Universal Synaptics, is attacking costs associated with readiness by providing superior warfighting support through an Intermittent Fault Detection & Isolation System (IFDIS™). Today’s defense environment requires responsive and affordable solutions to global weapon system support challenges. United States forces are simultaneously engaged in multiple humanitarian assistance and disaster recovery operations, rebuilding a nation in Iraq, drawing-down major combat operations in Afghanistan, fighting terrorism around the globe, and maintaining a deterrent to strategic-level threats like cyber warfare and weapons of mass destruction. However, as operations have increased, the Department of Defense’s (DoD’s) ability to economically sustain them has become increasingly challenging. The high, sustained operations tempo over the past decade in harsh environments has eroded weapon system readiness and reduced expected life span. Recapitalization of systems has been complicated by sequestration and the cancellation of weapon systems modernization programs. In light of these realities, the Services are seeking ways to improve maintenance capabilities, reduce No Fault Found (NFF) and increase operational readiness while simultaneously reducing life-cycle and maintenance costs.

A solution to this problem has been developed and proven under a Small Business Innovation Research (SBIR) initiative. The Intermittent Fault Detection & Isolation System™ (IFDIS™) was specifically designed to detect and isolate intermittent faults in electronic wiring. Its initial adaptation was to detect and isolate the intermittent faults in the F-16 AN/APG-68 Radar System Modular Low Power Radio Frequency unit (MLPRF) chassis. IFDIS testing during the first few years of operation yielded unprecedented results. The operational reliability of the IFDIS tested MLPRFs has more than tripled. A cost benefit of over $114 million has already been realized with an investment of only $2.2 million.

We welcome each and every one of you to stop by booth P311 to learn more from industry leaders, and maintainers from all levels at this distinctive, first class event – the maintenance community’s primary venue for networking and content sharing.