Advanced Modeling and Simulation, Tooling and Manufacturing for Low Volume Vehicle Component Redesign and Production

NCMS Project #: 142056

Problem: As vehicle and equipment fleets age, the companies that manufactured these legacy assets are either no longer in business, or simply won’t support making replacement parts that are not profitable for them.  This leads to an overall problem of diminishing manufacturing sources for older hardware that is still in useful service.  One of the main challenges remains to replace or redesign custom low-volume components at an affordable price to meet consumer demands.

Benefit: The goal is to leverage lessons learned and transition the processes and procedures as an effective and affordable solution for similar maintenance issues requiring low-volume component redesign and production across a wider range of other vehicles, aircraft, ships, and locomotives in the public and private sector.

Solution/Approach: A military vehicle will serve as the ideal platform for investigating the latest and most advanced commercial engineering and manufacturing technologies to help resolve this critical maintenance and sustainment issue.  This project will leverage advanced modeling and simulation, soft tooling, and manufacturing technologies and processes used at a commercial automobile supplier to manufacture redesigned vehicle doors that are cheaper to produce, easier to maintain, and last longer than the original doors.

Impact on Warfighter:

  • Faster processes 
  • Higher quality components 
  • Decrease maintenance down time  
  • Reduce overall maintenance and sustainment costs 
  • Improve warfighter readiness 

DOD Participation:

  • U.S. Army PM Transportation Systems
  • U.S. Army Ground Vehicle Systems Center (GVSC)
  • Red River Army Depot

Industry Participation:

  • Rose-A-Lee Technologies
  • NCMS

Benefit Area(s):

  • Cost savings
  • Maintenance avoidance and reliability
  • Safety
  • Improved readiness
  • Durability
  • Reliability improvement
  • Lightweighting

Focus Area:

  • Reliability improvement