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January 30, 2019 | International, Aerospace

Iwakuni Marines use 3D printers to revolutionize maintenance for fighter jets

By JAMES BOLINGER | STARS AND STRIPES

MARINE CORPS AIR STATION IWAKUNI, Japan — Using 3D printers, Marines based in southern Japan created two products that reduce the time it takes to repair F/A-18 Hornets and may save the Defense Department money.

Called an engine ship kit, the first innovation is a set of plastic clips and plugs to prevent oil and hydraulic fluid leaking from aircraft engines removed for repairs. The other is a tool that helps maintainers grease the bearings on the F/A-18's high-speed Gatling gun.

Designed by Marines from MCAS Iwakuni's Marine Aviation Logistics Squadron 12, the engine ship kit will have an immediate impact on operations, squadron commander Lt. Col. Javier Garcia recently told Stars and Stripes.

The kit eliminates the need for maintainers to travel to austere locations to drain oil and hydraulic fluids so an engine can be taken safely back to Iwakuni for repair.

The plastic drain plugs prevent the fluid from leaking and the clips ensure the plugs are not dislodged as the engine is readied for transport.

The kit is the brain child of 1st Lt. Simon Miller and Chief Warrant Officer 3 Mark Willems, who needed to get a broken F/A-18 engine from Wake Island to MCAS Iwakuni late last year.

The engine began to leak while a C-130 crew tried to load it, Garcia said. In the past, a team of maintenance Marines would have traveled to the location to prepare the engine for safe transport, but that takes away from their mission at MCAS Iwakuni.

To solve the problem, Willems had the idea of creating plugs that would stop the leaks. Miller created the pieces using 3D drafting software and MALS 12's new 3D printers.

“I'm not really sure why no one thought to make this kind of kit before, but this design is going to have an impact across the Navy and Marine Corps,” Garcia said.

The same team behind the engine ship kit also created a tool that makes it easier for maintenance Marines to grease the bearing on the F-18's M61A Vulcan, a Gatling-style rotary cannon that can fire 6,000 rounds a minute.

The bearing on the cannon must be packed with grease every 30,000 rounds, a job that used to take two Marines more than 30 minutes, said Cpl. Christian Smellie, an aviation life-support systems technician who works at Iwakuni's 3D printing lab.

Full article: https://www.stripes.com/news/pacific/iwakuni-marines-use-3d-printers-to-revolutionize-maintenance-for-fighter-jets-1.566446

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  • Contract Awards by US Department of Defense - February 14, 2019

    February 18, 2019 | International, Aerospace, Naval, Land, C4ISR, Security, Other Defence

    Contract Awards by US Department of Defense - February 14, 2019

    NAVY GE Aviation Systems LLC, Vandalia, Ohio, is awarded a $68,177,707 long-term contract for repair of 33 items that are part of the G2/G3 generator converter units used on the F/A-18 aircraft. The contract will include a three-year contract with one two-year option period which, if exercised, the total value of the contract will be $87,116,502. Work will be performed in Coronado, California (70 percent); and Vandalia, Ohio (30 percent). Work is expected to be completed by February 2022; if the option is exercised, work will be completed by February 2024. Working capital funds (Navy) will be obligated as individual task orders are issued and funds will not expire at the end of the current fiscal year. This contract was a sole-source, non-competitive requirement pursuant to the authority set forth in 10 U.S. Code 2304(C)(1) and Federal Acquisition Regulation 6.302-1. The requirement was posted to the Federal Business Opportunities website and the Navy Electronic Commerce Online website, with one offer received. Naval Supply Systems Command Weapon Systems Support, Philadelphia, Pennsylvania, is the contracting activity (N00383-19-D-UJ01). CDM Federal Programs Corp., doing business as CDM Smith, Fairfax, Virginia, is awarded a $33,000,000 modification to increase the maximum dollar value of an indefinite-delivery/indefinite-quantity contract (N62470-15-D-4002) for architect–engineering services for utilities engineering and management support projects located throughout the Naval Facilities Engineering Command (NAVFAC) area of responsibility (AOR) worldwide. The primary tasks anticipated under this contract include producing utility system master plans, engineering studies, surveying, field testing, hydraulic modeling, recommended treatment and distribution improvements, electric load and demand modeling, arc-flash and safety hazard analysis, relay coordination, life cycle cost analysis, 1391 documentation and design, development and implementation of standard processes and tools to inventory and manage utility assets, collecting direct condition ratings; performing risk assessment on functional groups of assets, creating a risk based investment strategy, and capital improvement plans; development of standard operating procedures, preventive maintenance plans, and operator training; process and instrumentation drawings/electric system one-line drawings for utility systems; development of Geographic Information Systems for utilities using GPS and mobile field data development and integration of utility information systems to increase the reliable, safe and efficient delivery of utility services; development of best practices and documentation, development of staffing plans, and organizational analysis of public works departments with staffing recommendations, organizational improvements and other related services. 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This order is for the procurement of the TCDL MST STE system equipment, program management, and respective support, integration, and fitting out. Work will be performed in Salt Lake City, Utah, and is expected to be completed by September 2023. Fiscal 2017, 2018, and 2019 shipbuilding and conversion (Navy) funding in the amount of $25,424,516 will be obligated at time of award and will not expire at the end of the current fiscal year. The Naval Sea Systems Command, Washington, District of Columbia, is the contracting activity. L-3Communications Vertex Aerospace LLC, Madison, Mississippi, is awarded a $23,420,937 firm-fixed-price, indefinite-delivery/indefinite-quantity contract to provide contractor owned and operated aircraft for airborne threat simulation capabilities to train shipboard and aircraft squadron weapon systems operations and aircrew to counter enemy electronic warfare and electronic attach operations. 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The estimated aggregate ceiling for all contracts is $20,000,000, with the companies having an opportunity to compete for individual orders. These contracts provide for various types of commercially-available electronic components, manufactured from several different materials, in different forms, shapes, sizes, and complexity in support of the Naval Air Warfare Center Weapons Division's Applied Manufacturing Technology Division (Code 475000D). Work will be performed in Portland, Oregon (20 percent); San Diego, California (20 percent); Laguna Beach, California (20 percent); Yucaipa, California (20 percent); and El Cajon, California (20 percent), and is expected to be completed in February 2024. Fiscal 2019 working capital funds (Navy) in the amount of $21,886 will be obligated at time of award, none of which will expire at the end of the current fiscal year. These contracts were competitively procured via a 100 percent small business set-aside electronic request for proposals with six offers received. The Naval Air Warfare Center Weapons Division, China Lake, California, is the contracting activity. Lockheed Martin Rotary and Mission Systems, Manassas, Virginia, is awarded a $17,288,213 cost-plus-incentive-fee contract modification to previously-awarded contract N00024-17-C-6259 to exercise options for Navy equipment, engineering services and required material. Work will be performed in Manassas, Virginia (65 percent); Clearwater, Florida (32 percent); Syracuse, New York (2 percent); and Marion, Florida (1 percent), and is expected to be completed by September 2022. Fiscal 2019 other procurement (Navy); fiscal 2019 shipbuilding and conversion (Navy); and fiscal 2019 research, development, test and evaluation (Navy) funding in the amount of $16,823,290 will be obligated at time of award and will not expire at the end of the current fiscal year. The Naval Sea Systems Command, Washington, District of Columbia, is the contracting activity. Bell Boeing Joint Project Office, Amarillo, Texas, was awarded $10,656,686 for modification P00002 to a previously issued delivery order (N0001918F1645) placed against basic ordering agreement, N00019-17-G-0002. This modification exercises the option to procure 12 A-Kits to retrofit legacy fleet aircraft with the AN/APR-39D(V)2, AN/AAQ-24B(V)27, and the ALE-47 Power Performance Computing, upgrading the MV-22 from Configuration A to Configuration C. 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(Awarded Feb.11, 2019) AIR FORCE Tecolote Research Inc., El Segundo, California, has been awarded a $38,784,990 cost-plus-fixed-fee contract for Space and Missile Systems Center acquisition and financial support services. This contract provides the Remote Sensing Systems Directorate with a broad range of acquisition, financial, and administrative capabilities to execute effective and responsive integrated program management of space-related research, development, production, sustainment, and lifecycle acquisition activities. Work will be performed in El Segundo, California, and is expected to be complete by Aug. 17, 2024. This award is the result of a competitive acquisition and one offer was received. Fiscal 2019 space procurement funds in the amount of $939,196; fiscal 2019 operations and maintenance funds in the amount of $707,006; and fiscal 2019 research, development, test and evaluation funds in the amount of $4,952,516 are being obligated at the time of award. Space and Missile Systems Center Remote Sensing Systems Contracting Division, Los Angeles Air Force Base, California, is the contracting activity (FA8810-19-F-0003). Northrop Grumman Systems Corp., Redondo Beach, California, has been awarded a not-to-exceed $20,000,000 indefinite-delivery/indefinite-quantity (IDIQ) contract for Advanced Turbine Technologies for Affordable Mission (ATTAM) capability Phase I. The mission of the ATTAM Phase I program is to develop, demonstrate, and transition advanced turbine propulsion, power and thermal technologies that provides improvement in affordable mission capability. This approach extends to a range of legacy, emerging, and future military propulsion, power and thermal technology needs in multiple applications. Work will be performed in Redondo Beach, California, and is expected to be completed by Feb. 8, 2027. This award is the result of a competitive acquisition and 54 offers were received. 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Work will be performed in Arlington, Virginia, with an expected completion date of March 2020. Fiscal 2019 research and development funds in the amount of $21,769,143 are being obligated at time of award. The Defense Advanced Research Projects Agency, Arlington, Virginia, is the contracting activity. U.S. TRANSPORTATION COMMAND Vane Line Bunkering Inc., Baltimore, Maryland, has been awarded contract modification (P00030) on contract HTC71113CW015 in the amount of $16,952,486. This modification provides continued transportation of bulk jet fuel and marine diesel fuel by barge for the Defense Logistics Agency-Energy in the U.S. Atlantic Region. Performance is from Mar. 1, 2019, to Aug. 31, 2019. Fiscal 2019 defense working capital funds were obligated at award. This modification brings the total cumulative face value of the contract to $139,538,998 from $122,586,512. U.S. Transportation Command, Directorate of Acquisition, Scott Air Force Base, Illinois, is the contracting activity. WASHINGTON HEADQUARTERS SERVICES Johns Hopkins University, Applied Physics Laboratory, Laurel, Maryland, has been awarded a $9,763,000 cost-plus fixed-fee contract. The contract is to provide assessments and alternatives of offensive capabilities within the domains of air, land, sea, space and cyberspace, missions and warfare areas that asymmetrically mitigate threat effectiveness, impose cost, and/or create ambiguity in adversary decision-making. Work performance will take place in the National Capital Region, including Arlington and Alexandria, Virginia. Fiscal 2018 - fiscal 2019 research, development, test, and evaluation funds in the amount of $5,460,000; fiscal 2019 – fiscal 2020 research, development, test, and evaluation funds in the amount of $3,576,000; and fiscal 2019 operations and maintenance funds in the amount of $727,000 are being obligated on this award. The expected completion date is Dec. 29, 2019. 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  • Contract Awards by US Department of Defense - December 26, 2018

    December 27, 2018 | International, Aerospace, Naval, Land, C4ISR, Security

    Contract Awards by US Department of Defense - December 26, 2018

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The maximum dollar value including the base year and four option years for all six contracts combined is $99,000,000. The work to be performed provides for construction services. The contractor shall provide all labor, supervision, engineering, materials, equipment, tools, parts, supplies and transportation to perform all work described in the specifications. Huang-Gaghan JV Two is being awarded task order 0001 at $2,942,286 for the seed project A-59 new mechanical room and central hot water system, at Naval Research Laboratory Washington, District of Columbia. Work for this task order is expected to be completed by January 2019. All work on this contract will be performed primarily within the NAVFAC Washington AOR to include District of Columbia (40 percent); Virginia (40 percent); and Maryland (20 percent). The term of the contract is not to exceed 24 months, with an expected completion date of January 2020. Fiscal 2019 supervision, inspection, and overhead; and fiscal 2019 Navy working capital funds in the amount of $2,942,286 are obligated on this award and will expire at the end of the current fiscal year. Future task orders will be primarily funded by military construction (Navy); operations and maintenance (Navy and Defense Logistics Agency); and Navy working capital fund. This contract was competitively procured via the Navy Electronic Commerce Online website, with 18 proposals received. These six contractors may compete for task orders under the terms and conditions of the awarded contract. Naval Facilities Engineering Command, Washington, District of Columbia, is the contracting activity. 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U.S. Army Contracting Command, Redstone Arsenal, Alabama, is the contracting activity (W58RGZ-19-C-0008). AIR FORCE Alliant Techsystems Inc., Fort Worth, Texas, has been awarded a $36,570,512 firm-fixed-price modification (P00045) to contract FA8106-16-C-0004 that exercises Option Year Three for contractor logistic support. This contract provides the Iraqi Air Force's Cessna 208 fleet and the 208/172 Trainer fleet with contractor logistic support. Work will be performed in Iraq and is expected to be completed Dec. 31, 2019. This contract involves 100 percent foreign military sales to Iraq and is the result of a sole-source acquisition. Air Force Life Cycle Management Center, Tinker Air Force Base, Oklahoma, is the contracting activity. U.S. SPECIAL OPERATIONS COMMAND Rockwell Collins Inc., Cedar Rapids, Iowa, has been awarded a $35,000,000 contract modification for an existing non-competitive single award, indefinite-delivery/indefinite-quantity contract (H92241-15-D-0001) to provide post-deployment software support for the Common Avionics Architecture System. This modification increases the contract ceiling amount from $107,328,000 to $142,328,000. Each individual task order will be funded with procurement; research, development, testing and evaluation; and operations and maintenance appropriations, as appropriate, from the correct fiscal year at the time of obligation. This contract is not multiyear. Ordering periods will end on Nov. 30, 2019. This contract was awarded through noncompetitive procedures in accordance with Federal Acquisition Regulation 6.302-1. U.S. Special Operations Command, Tampa, Florida, is the contracting activity. *Small business https://dod.defense.gov/News/Contracts/Contract-View/Article/1721253/

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