Attachment 1 - Statement of Objectives.pdf

Controlled Unclassified Information (CUI)

US Air Force

Composite Overwrapped Pressure Vessel (COPV) Cases

Statement of Objectives (SOO)

F3KTK73173AW01

1 July 2023 Version 2

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Table of Contents

1. BACKGROUND

2. SCOPE

3. PARAMETERS

4. GOVERNMENT FURNISHED MATERIAL

5. OBJECTIVES

6. CLIN 0001 – Kickoff Meeting

7. CLIN 0002 – Preliminary Design Review

8. CLIN 0003 – First Article Production and Inspection

9. CLIN 0004 – Production Run

1. BACKGROUND

1.1 The Air Force has a requirement to purchase Composite Overwrapped Pressure

Vessel (COPV) cases via a competitive, open-solicitation effort. The purchase request is focused at the rotational molding industry.

1.2 The Technical Applications Center (TAP) program is moving away from the older, traditional, 50-pound stainless-steel pressure spheres and going with a much lighter, COPV design (SCUBA tank-type shape). A new case has been designed by the government and we are now ready to go into production. These new cases will transport two (2) COPVs in each case.

2. SCOPE

2.1 This Statement of Objectives (SOO) defines the efforts to be accomplished by the selected vendor.

2.2 All safety practices required for personnel safety and equipment shall be strictly adhered to.

2.3 All standards of workmanship will be strictly adhered to.

3. PARAMETERS

3.1 The scope of this effort is use the government-provided drawings and models to create the tooling/molds for COPV cases. Further, a large production run to follow.

3.2 Case material to be Low Density Polyethylene (LDPE Resin).

3.3 Case wall thickness will be 0.125 inches (minimum).

3.4 Case measurements are on drawings and models.

4. GOVERNMENT FURNISHED MATERIAL

4.1 The government will provide the following:

4.1.1 The government will provide one COPV for vendor fit checks.

4.1.2 Case drawings and associated models (.pdf and .STEP format).

5 OBJECTIVES

5.1 There are four CLINs defined within this SOO. The following objectives and vendor responsibilities are described in greater detail in the following sections:

5.2 CLIN 0001 – KICKOFF MEETING

5.2.1 Kickoff Meeting - The vendor will host a kickoff meeting at their facility within two weeks of contract award. Vendor to provide a briefing on rotational molding technology, manufacturing process and discuss the general vendor capability.

5.2.2 The vendor will be tasked to design a rotational mold(s), with all necessary tooling to produce COPV cases. The tooling and molds are a deliverable to the government with this effort. The vendor and the government to discuss storage of these government-owned assets.

5.2.3 The vendor and the government to specifically discuss the placement of case handles and the possible addition of additional case handles.

5.2.4 The vendor and the government to specifically discuss valve cover interfaces.

5.2.5 The vendor will schedule the Preliminary Design Review (PDR). The meeting will occur no later than 60 days after the kickoff meeting. The PDR will be at the vendor’s location.

5.3 CLIN 0002 - PRELIMINARY DESIGN REVIEW

5.3.1 (CDRL 0002) The Vendor will present the case mold design for review;

detailed in the draft Technical Data Package (TDP). Draft TDP to include the following (an any other applicable tech data):

• Material Certs

• Drilling Templates

• Nylon Strap Templates

• Hardware material data sheets

5.3.2 (CDRL 0001) The vendor will also present the draft drawings/models at this review.

- NOTE -

While the government is providing drawings/models for this effort, we realize some drawing changes/additions/updates may be necessary to arrive at an acceptable final design (specifically attention to case handle placement and valve cover interfaces)

5.3.3 (CDRL 0001 & 0002) The government has 21 calendar days to formally accept the PDR (to include the draft TDP & draft drawings/models). The vendor will not proceed with first article production until they have received formal government acceptance of the PDR from Lackland AFB contracting; this is referred to as the “Authority to Proceed” (ATP). The government reserves the right to reject the PDR for rework by the vendor (at the vendor’s expense) or to terminate the contract completely.

5.3.4 (CDRL 0001 & 0002) If the Vendor fails the PDR, the government will allow

30 days for the vendor to resubmit their corrected draft TDP and draft drawings/models for re-evaluation. This will either result in another failure, with a possible contract termination, or a pass with an ATP.

5.4 CLIN 0003 – FIRST ARTICLE PRODUCTION AND INSPECTION

5.4.1 Upon receipt of the ATP from Lackland AFB contracting, the vendor will manufacture two first article cases. When complete, the cases will be shipped to Lackland AFB TX (San Antonio, TX) for inspection/acceptance. The government will have 21 calendar days to fully inspect the case.

5.4.2 The First Articles will be tested in accordance with the following criteria:

5.4.2.1 (CDRL 0001) Drawing Test - Does the case positively compare to the draft drawings/models. This will be done by measuring the case, keying on critical dimensions.

5.4.2.2 Fit Test - COPVs will be fit tested in the new case assembly.

5.4.2.3 Stacking Test – the cases will be stacked on top of each other to endure they stack easily.

5.4.2.4 SIL Fit Test – the case will be loaded into the CCSD Software Integration Lab (SIL); or operational rack. The assembly must fit in all 24 positions (locations are identical). The assembly must engage with top rack and base constraints at each position.

5.4.2.5 Pressurization Test - COPVs will be pressurized in the case. The government will ensure the COPV fits securely in the case when pressurized.

5.3.2.6 Valve and Case Cap Test – The government will ensure the COPV valves can be accessed during operation and covered during storage/shipping.

5.4.2.7 Inspection Pass/Fail. The government will complete its inspections/tests within 21 calendar days of receipt of first article cases.

- Pass – (CDRL 0001 & 0002) If the first article, draft drawings/models and draft TDP are accepted, the Critical Design Review (CDR) may be waived. A pass also will result in a formal ATP with the production run.

Remember ATP are sent only by Lackland Contracting.

- Fail - If the first article, draft drawings/modes and draft TDP are not accepted, the vendor will be made aware of what is unacceptable to the government. The vendor will schedule a CDR to take place within 30 calendar days of the failure notification.

5.4.3 Critical Design Review – the vendor will schedule a CDR to take place within 30 calendar days of notification of the failed first article.

5.4.3.1 The government will review the updated draft TDP, updated drawings/models, design, and production effort that should lead to the manufacture of serviceable cases. The vendor may have to present a new case for inspection.

• Pass – if the revised documentation/product meets the government’s need, the vendor will receive a formal ATP from contracting.

• Fail – if the revised product still does not meet the government’s needs the contract may be terminated (with no production run).

5.3.3.2 The government has 15 working days to formally review the CDR. The vendor will not proceed with the production run until they have received formal government acceptance of the CDR from Lackland AFB and the

ATP.

5.5 CLIN 0004 – PRODUCTION RUN

5.5.1 Upon receipt of the ATP, the vendor will begin their production run.

5.5.2 (CDRL 0001) The Vendor will submit the Final TDP.

5.5.3 (CDRL 0002) The Vendor will submit the Final drawings/models.

5.6 PACKING / SHIPPING / TRANSPORTATION

5.6.1 Incremental shipping is authorized and encouraged.

5.6.2 Cases will be packed to prevent damage during shipping. Cases will be strapped to pallets for shipping. Cases will not be stacked higher than three cases high.

5.6.3 COPV cases will be shipped to the following address:

MARK FOR: ROBERT SWANSON (210) 925-8475

CENTRAL RECEIVING

TECHNICAL APPLICATIONS PRODUCTS

230 HALL BLVD, STE 158

SAN ANTONIO, TX 78243