SOW.docx

STATEMENT OF WORK - 70Z03820QB2000003

STATEMENT OF WORK (SOW)

FOR

HH65 COOLING MANIFOLDS

1.0 SCOPE

A requirement exists for the manufacture of 110 shipsets of additive manufactured cooling manifolds for the United States Coast Guard (USCG) H-65 Helicopter cockpit system upgrade. This requirement includes procurement of First Article and production quantities of additive manufactured manifolds In Accordance With (IAW) US Coast Guard design.

2.0 BACKGROUND

The USCG operates a fleet of 98 H-65 aircraft. The H-65 fleet is being modernized to include a new Multifunctional Display (MFD) system in the cockpit instrument panel. The new MFD configuration requires the addition of cooling manifolds to direct heat away from the MFD’s and ensure safe operation of aircraft cockpit display systems. The cooling manifolds are separated in to three (3) distinct sets; MFD Cooling manifold RH (968-25-25), MFD cooling manifold LH (968-25-24), & copilot manifold (968-25-26), each set with its own drawing and CAD files. MFD cooling manifold LH & MFD cooling manifold RH each contain three (3) separate parts to be printed, the copilot is a single piece. A ship set is defined as all parts listed in table 2.1.

Table 2.1 MFD Cooling Manifold Parts

2.1. Applicable Documents and Design Criteria

2.1.1. Government Documents. The documents listed in table 2.2 are necessary to manufacture the parts defined in this SOW. CAD files and drawings will be made available upon request from the vendor. Before obtaining copies of these documents, contractors shall be registered in the Defense Logistics Agency’s Joint Certification Program. More information on this certification can be found at DLA JCP Page. After ensuring registration, the contractor shall complete DHS Form 11000-6, Sensitive but Unclassified Information Non-Disclosure Agreement. Complete the form with required signature, and email it to Dawn.B.O’Connor@uscg.mil. If the form is sent without the required signature, it will be invalid, the technical data will not be released, and the form must be resubmitted. Copies of CAD files and drawings will not be posted to the Federal Business Opportunities website. The USCG will only release drawings and CAD files to United States (U.S.) businesses that have followed the above procedures. The drawings will not be released to any foreign entity. If the U.S. business plans to release these documents to any foreign entity, they shall provide the USCG with a copy of a valid Technical Assistance Agreement (TAA) and DSP-5 that authorizes the release of this information to that entity.

Table 2.2 Government Documents

2.1.2. USCG Design Data. Cooling manifolds shall be printed to meet the requirements called out in drawings 968-25-26, 968-25-25, & 968-25-24, and associated CAD files. For 968-25-25 & 968-25-24, only items 1, 2 &3 are required as listed in table 2.1. Item 4 of the drawing is not a 3D printed part and is utilized in assembly of the manifold upon installation to the aircraft. The contractor will not be responsible for providing item 4 of the drawing. The manifold material shall be Nylon 11 FR Selective Laser Sintering (SLS) printing. The cooling manifold shall also meet all requirements of this SOW during the verifications specified herein. An acceptable First Article (FA) of the parts listed in table 2.1 shall be provided by the contractor to verify form, fit and function. Upon completion of FA form, fit & functional testing the Coast Guard will authorize Full Rate Production (FRP) of 110 ship sets, as listed in table 2.1, of the cooling manifold. First Article shall be delivered no later than 30 calendar days After Receipt of Order (ARO). Full production shall not commence until government acceptance of first article. Remaining production quantities of 110 ship sets shall be delivered at a minimum rate of ten (10) production shipsets within thirty (30) calendar days after acceptance of first article and then twenty (20) every thirty (30) calendar days until all quantities are delivered.

The Cooling manifold CAD files and drawings include all the necessary detailed dimensions and materials required to manufacture the cooling manifolds. The manifolds shall meet tolerances identified on the ALC drawing.

2.2. Design Criteria

2.2.1. Airworthiness. The aircraft shall safely perform all assigned missions in accordance with FAA Part 29 (14 CFR 29) Airworthiness Standards: Transport Category Rotorcraft (Amendment 16), Part 91 General Operating and Flight Rules and the USCG Air Operations Manual, COMDTINST M3710 (series). Modifications to the H-65 must be designed to meet or exceed the requirements of FAA FAR 29 & FAA FAR 21. Exceptions to FAA FAR 29 & FAA FAR 21 requirements are allowed for public use aircraft. Deviations from the FAA FAR 29 & FAA FAR 21 requirements must be approved by the USCG.

2.2.2. Cooling Manifolds. Only Nylon 11 FR printed via SLS printing is acceptable for manufacture of the parts listed in this SOW as this is the only method and material approved by the aircraft OEM. Each part designated in the drawings and listed in table 2.1 must be printed in one piece, as designed. There will be no exceptions for splitting the parts into pieces and then bonding them together after printing.

2.2.3. Finishes and Protective Coatings. No additional protective coating or finish is required for the cooling manifolds.

2.2.4. Marking. The cooling manifolds shall be marked IAW drawings 968-25-26, 968-25-25 & 968-25-24. The part number of each component shall be placed to enable convenient viewing. Each component shall be individually labeled.

2.2.5. Interchangeability. Cooling manifolds having the same part number shall be directly and completely interchangeable with respect to installation and performance.

2.2.6. Non Reoccurring Engineering (NRE) - The Contractor shall use commercially reasonable efforts to perform the manufacturing services in conformity with the design criteria set forth in section 2.1 and 2.2 of this SOW. Service charges, and other costs incurred in the performance of the manufacturing services, shall be included in the one-time NRE.

3.0 TECHNICAL DESCRIPTION

3.1. Performance Specification. First Article and Production cooling manifolds shall be built in accordance with material specifications as presented in section 2.1 and 2.2 of this SOW. Cooling manifold interface with the aircraft multifunctional displays is required to ensure safe and effective USCG mission execution.

3.2. Mechanical Interface Requirements. The cooling manifold will require an interface with the current components housed in the aircraft instrument panel. To achieve that interface, the manifold must be manufactured to the tolerances noted on the USCG CAD files and drawings listed in table 2.2.

3.3. Performance & Capabilities.

3.3.1. Design Deviation Requirements. The Cooling manifolds shall comply with the references listed in this SOW. If the Contractor deviates from the requirements in table 2.2 and section 2.2 of this SOW, the contractor shall describe the deviation and seek USCG approval prior to implementation of design deviation.

4.0 PRODUCTION REQUIREMENTS

4.1. First Article. The contractor shall deliver one (1) first article of all parts listed in table 2.1 that form a ship-set within thirty (30) calendar days ARO to ALC for first article acceptance. The first article must pass ALC acceptance NRE testing prior to approval for full production manufacture. A copy of print coupon testing shall be included with delivery of first article ship-set.

4.2. Cooling Manifold Production. The Contractor shall provide new production Cooling manifolds. The Contractor shall provide all parts, material, labor, tooling, test equipment and facilities needed to produce Cooling manifolds at the firm-fixed prices specified.

4.3. Production Buys. If the Contractor’s first article is approved by ALC, new production quantities may be purchased from the Contractor. The Contractor shall not ship new production quantities, IAW the schedule listed in section 7.0, until they receive notification from ALC Contracting.

5.0 QUALITY ASSURANCE PROVISIONS

5.1. Responsibility for Inspections and Tests. The Contractor shall establish an inspection system in accordance with FAA and/or DoD procedures for all components. The USCG reserves the right to review the Contractor operation and/or facilities at any time during the period of the contract.

5.2. Testing. The Contractor shall ensure Cooling manifold parts printed from Nylon 11 FR (SLS Printing) pass Flame, Smoke, & Toxicity testing IAW Federal Aviation Regulation (FAR) 25.853. Print coupons shall be provided during the part run at the beginning, middle, and end of each batch. Print coupons shall be tested by the Contractor IAW the requirements listed in table 5.1. Test results shall be delivered with each batch upon delivery to ALC.

Table 5.1 Material Testing Specification Documents

5.2.1. First Article Acceptance. First Article fit & function acceptance will be conducted on an aircraft located at the Aviation Logistics Center Elizabeth City NC. The Contractor shall deliver first article Cooling Manifold ship-sets for verification and acceptance by the USCG and include results of Flame, smoke, & Toxicity testing.

5.3. Preliminary Inspection. All parts produced or modified under the provisions of this contract must be airworthy and suitable for installation on USCG aircraft.

5.4. Final Inspection and Acceptance. Final inspection and acceptance of material under this contract shall be performed at destination by local Receiving personnel and will consist of count, condition and verification that all required documentation has been provided. ALC considers components RFI upon acceptance. Components determined to be non-RFI upon installation may be returned to the Contractor with a Quality Deficiency Report for repair at no additional cost to the USCG.

5.5. Configuration Management Program. The Contractor shall have an established Configuration Management Program with control systems in place for the Cooling manifolds including configuration identification of each hardware item for the contract life. Any changes to the dimensions or materials used to produce the cooling manifolds must be approved by the USCG.

5.5.1. Serialization/Traceability. Traceability. Each delivery shall come with a certificate of conformance and include the following data:

· Material lot number & date code logged when used for printing

· Printer Serial Number logged for each part

· S/N on each part to correspond to material/printer used

6.0 SPECIAL INSTRUCTIONS

6.1. Warranty. The government may accept the Contractor’s standard commercial warranty. The warranty period will commence upon installation or twelve months after delivery whichever comes first.

6.2. First Article Shipment Notification. Contractor shall notify the Contract Specialist via e-mail upon shipment of first article at Dawn.B.O’Connor@uscg.mil. The e-mail shall include first article tracking number and electronic copies of flame, smoke, and toxicity test results.

7.0 DELIVERY SCHEDULE

NOTE: Early deliveries are desired and acceptable.

7.1. GOVERNMENT PROPOSED DELIVERY.

P/N 968-25-24-1

P/N 968-25-24-2

P/N 968-25-24-3

P/N 968-25-25-1

P/N 968-25-25-2

P/N 968-25-25-3

P/N 968-25-26

P/N 968-25-24-1

P/N 968-25-24-2

P/N 968-25-24-3

P/N 968-25-25-1

P/N 968-25-25-2

P/N 968-25-25-3

P/N 968-25-26

P/N 968-25-24-1

P/N 968-25-24-2

P/N 968-25-24-3

P/N 968-25-25-1

P/N 968-25-25-2

P/N 968-25-25-3

P/N 968-25-26

P/N 968-25-24-1

P/N 968-25-24-2

P/N 968-25-24-3

P/N 968-25-25-1

P/N 968-25-25-2

P/N 968-25-25-3

P/N 968-25-26

P/N 968-25-24-1

P/N 968-25-24-2

P/N 968-25-24-3

P/N 968-25-25-1

P/N 968-25-25-2

P/N 968-25-25-3

P/N 968-25-26

P/N 968-25-24-1

P/N 968-25-24-2

P/N 968-25-24-3

P/N 968-25-25-1

P/N 968-25-25-2

P/N 968-25-25-3

P/N 968-25-26

P/N 968-25-24-1

P/N 968-25-24-2

P/N 968-25-24-3

P/N 968-25-25-1

P/N 968-25-25-2

P/N 968-25-25-3

P/N 968-25-26