Draft Requirement - Machining and Fabrication Services.pdf

FEDERAL BUREAU OF INVESTIGATION

FINANCE AND FACILITIES DIVISION | PROCUREMENT SECTION

Machining and Fabrication Services

For the

Operational Technology Division (OTD) - Machining and Fabrication Group (MFG) / ET Operations and

Development Unit (EODU)

Draft Requirement

01/31/2025

(U) Description of Services/Introduction The MFG/EODU is seeking the acquisition of mechanical engineering and machinist support services.

These contract personnel will assist MFG government employees with the design and fabrication of complex mechanical parts and systems to meet MFG and field requirements for operational support.

(U) Background The MFG provides custom electrical and mechanical design and fabrication services for the Bureau, specifically for operational and investigative support. MFG possesses a full suite of typical machine shop equipment (manual and CNC mills and lathes, press brakes, sheers, etc.) that are used to fabricate the various parts that are designed by MFG engineers.

(U) Requirements / Specifications

(U) Mechanical Engineer

(U) Work Requirements

(U) The mechanical engineer must be able to design new mechanical parts and/or systems, modify existing parts, and use available materials to render new or modified solutions when directed. Problems and developed solutions span all aspects of law enforcement not addressed by commercial products and can range from quick reaction needs to long term development projects. Design activities involve a variety of areas including mechanical, electro-optical, and electronic system integration. The engineer will be involved in product design, prototyping, product improvement iterations and manufacturing and must be able to effectively communicate and work with team members on assignments. The engineer will have design responsibility for small stand-alone projects, or portions of larger, more complex, multi-part projects under the direction and coordination of an MFG government engineer.

(U) The mechanical engineer must be able to perform the following duties:

Perform research and/or development engineering studies.

Review specifications, operational plans, technical advancements, etc., to gather supplementary data on which to base designs.

Create models and perform calculations, taking into consideration the project requirements, using computer-aided-design (CAD) software. Coordinate with engineers and machinists to avoid interferences and ensure proper integration of systems. Prepare preliminary and final designs of mechanical systems that meet all organizational standards.

Review working drawings and any design commitments made to users.

Review drawings and parts submitted by outside groups to determine if they conform to MFG and Bureau standards for fabrication. Review fabrication details and assess suitability of materials selected.

Communicate orally and in writing with Bureau management using appropriate documentation standards to provide status reports, design details, and research results.

Provide technical engineering advice to other engineering and technical personnel.

(U) Work will be performed in an office environment, but some tasks must be completed in a shop environment, lab environment, or in the field. There will be some periods of minor lifting, standing, sitting, and bending. Some tasks may involve exposure to dust, metals, paints, solvents, and various other chemicals and environmental hazards frequently present in a manufacturing/laboratory environment. Contract engineer may be required to travel outside to the Metro/DC area to gather first-hand information regarding requirements and operational methods. The contract engineer will report to the MFG group supervisor who will be considered the immediate supervisor in terms of job tasks.

Work is reviewed upon completion for technical adequacy and consistency with group and project objectives.

(U) Education and Experience Requirements A bachelor’s degree in mechanical engineering is required through an ABET accredited university program. Familiarity with related engineering fields, such as optical, electrical and electronics is helpful due to interactions with other groups within the division. Knowledge of machining is beneficial;

examples of machining knowledge include milling, lathing, welding, CNC & CAM, water jetting, etc.

Knowledge of plastics fabrication is beneficial, such as knowledge of injection molding, blow molding, single screw extrusion, rotational molding, thermoforming, thermoset casting, composite layup, plastic welding, etc. Knowledge and experience with prototyping technologies is beneficial; prototyping technologies include various additive manufacturing / 3D printing systems such as laser scanning, fused deposition modeling, and selective laser sintering. Knowledge and experience in quality control processes is beneficial, which involves traditional metrology techniques for part inspection, operation of CMM’s, and design verification.

(U) The engineer must have at least five (5) years of experience in mechanical engineering design not related to HVAC systems.

(U) General Machinist (Intermediate or Senior Level)

(U) Work Requirements

(U) General machinists will be responsible for the fabrication of unique components and assemblies in support of FBI operational needs, encompassing long term to quick reaction projects. Machinists must be able to perform the following duties:

Program, set up, and operate conventional and special purpose machines to fabricate metallic and nonmetallic parts, and assemble machined parts into complete units, applying knowledge of machine shop theory and procedures, shop mechanics, machinability of materials, and fabrication methods.

Consult with engineers and other personnel regarding product information, such as design, capacity and purpose, and types of material to be used to fabricate the product.

Design fixtures, tooling, and experimental parts to meet special engineering needs.

Set up and operate metalworking machine tools, such as a lathe, milling machine, or grinder to machine parts to specifications.

Verify conformance of parts to specifications using precision measuring devices.

May operate welding equipment.

Confer with engineers, production personnel, programmers, or others to resolve machining or assembly problems.

Set up and operate machines on trial run to verify accuracy of machine settings or programmed control data.

Fits and assembles parts into complete assemblies, using jigs, fixtures, surface plates, surface tables, hand tools, and power tools.

May train or advise other machinists in programming, set up, and operation of machine tools.

May use CAD tools to assist engineers in the design, fabrication, and assembly of parts.

(U) Work is typically performed in a machine shop environment, though some tasks may require work in the field or in outdoor spaces. The contract machinist must be able to lift at least 40 lbs. Some tasks may involve exposure to dust, metals, paints, solvents, and various other chemicals and environmental hazards frequently present in a manufacturing/laboratory environment. Contract machinists may be required to travel outside to the Metro/DC area to gather first-hand information regarding requirements and operational methods, or to assist with the assembly, installation, or fabrication of components and systems. The contract machinists will report to a government machinist (MFG Shop Foreman) as well as the MFG group supervisor. The MFG shop foreman will be considered the immediate supervisor in assigning work tasks. Work is reviewed upon completion for technical adequacy and consistency with group and project objectives.

(U) Education and Experience Requirements

(U) The education and experience requirements for a general machinist are a completed apprenticeship in a manufacturing or prototyping field and a minimum of two (2) years’ demonstrated machining experience in a manufacturing and/or prototyping environment; or an Associate’s degree and a minimum of one (1) year demonstrated experience in a manufacturing and/or prototyping environment;

or recognized certification(s) in the manufacturing industry and a minimum of four (4) years’ demonstrated experience in a manufacturing and/or prototyping environment. The machinist must have machine shop experience with manual lathes, manual milling machines, band saws, drill presses, and various metal fabrication hand tools. Machinist must have experience fabricating parts from drawings and documentation provided by engineers. Machinist must have a working knowledge of CAD software (e.g. SolidWorks) and should also have a general knowledge of sheet metal fabrication, welding, and simple computer controlled equipment such as a waterjet or Prototrax.

(U) To be considered senior level, the machinist must have a minimum of 10 years’ demonstrated experience in a manufacturing and/or prototyping environment.

(U) CNC Machinist (Intermediate or Senior Level)

(U) Work Requirements

(U) CNC machinists will be responsible for the fabrication of unique components and assemblies using general machining as well as CNC machining practices in support of FBI operational needs. CNC Machinists must be able to perform the following duties:

Program, set up, and operate CNC machines to fabricate metallic and nonmetallic parts.

Program, set up, and operate conventional and special purpose machines to fabricate parts, and assemble machined parts into complete units, applying knowledge of machine shop theory and procedures, shop mechanics, machinability of materials, and fabrication methods.

Consult with engineers and other personnel regarding product information, such as design, capacity and purpose, and types of material to be used to fabricate the product.

Design fixtures, tooling, and experimental parts to meet special engineering needs.

Verify conformance of parts to specifications using precision measuring devices.

May operate welding equipment.

Confer with engineers, production personnel, programmers, or others to resolve machining or assembly problems.

Set up and operate machines on trial run to verify accuracy of machine settings or programmed control data.

Fits and assembles parts into complete assemblies, using jigs, fixtures, surface plates, surface tables, hand tools, and power tools.

May train or advise other machinists in programming, set up, and operation of machine tools.

Uses CAD tools to assist engineers in the design, fabrication, and assembly of parts.

Is proficient in the use of CAM tools for creating CNC machine code used to fabricate complex parts.

(U) Work is typically performed in a machine shop environment, though some tasks may require work in the field or in outdoor spaces. The contract machinist must be able to lift at least 40 lbs. Some tasks may involve exposure to dust, metals, paints, solvents, and various other chemicals and environmental hazards frequently present in a manufacturing/laboratory environment. Contract machinists may be required to travel outside to the Metro/DC area to gather first-hand information regarding requirements and operational methods, or to assist with the assembly, installation, or fabrication of components and systems. The contract machinists will report to a government machinist (MFG Shop Foreman) as well as the MFG group supervisor. The MFG shop foreman will be considered the immediate supervisor in assigning work tasks. Work is reviewed upon completion for technical adequacy and consistency with group and project objectives.

(U) Education and Experience Requirements

(U) The education and experience requirements for a CNC machinist are an Associate’s degree and a minimum of two (2) years’ demonstrated experience using CNC manufacturing equipment; or a completed apprenticeship in a manufacturing or prototyping field and a minimum of four (4) years’ demonstrated experience using CNC manufacturing equipment; or recognized certification(s) in the manufacturing industry and a minimum of six (6) years’ demonstrated experience using CNC manufacturing equipment. The CNC machinist must also have machine shop experience with manual lathes, manual milling machines, band saws, drill presses, and various metal fabrication hand tools. The CNC Machinist must have experience fabricating parts from drawings and documentation provided by engineers, must have a working knowledge of CAD software (e.g. SolidWorks), and must be proficient in the use of CAM software (e.g. MasterCAM) for the programming of CNC machine code. The CNC machinist should also have a general knowledge of sheet metal fabrication and welding.

(U) To be considered senior level, the CNC machinist must have a minimum of 10 years’ demonstrated experience using CNC manufacturing equipment.

(U) Staffing Level

(U) The anticipated staffing level for this Contract is 3 FTE. The FBI reserves the right to re-evaluate staffing levels, as needed, to adapt to a changing climate.

Labor Category No. of Positions

Mechanical Engineer 1.0

General Machinist (Senior) 1.0

CNC Machinist (Senior) 1.0

(U) Place of Performance

(U) Services provided in support of this task order shall be performed at the OTD’s Engineering Research Facility within the security perimeter of the United States Marine Corps Base Quantico, VA. In addition, work may also be accomplished, as required, at other government facilities on an as needed basis in direct support of investigative requirements.

(U) Government Furnished Equipment or Information

(U) The Government shall provide contractor personnel assigned to this contract with a typical working environment, including office furniture and furnishings, secure and unclassified telephone service, storage for classified and unclassified materials, use of the Government's mail and courier services, and access to copiers, fax machines, personal computers (PCs) and related software. Personnel assigned to this contract will also have access to MFG’s internal network as well as all shop fabrication and assembly equipment and tools.

(U) Personnel Availability The Contractor’s normal workday will typically be within the hours of 6:00 a.m. and 6:00 p.m. Core work hours are 9:00 a.m. through 3:00 p.m. Flexibility within the normal workday shall be coordinated with the COR.

(U) In addition, the Contractor shall support FBI investigations, as needed, outside of the hours identified above. Due to the uncertain nature of mission critical and operationally time-sensitive investigations, support may be required outside of and / or in addition to the established core hours.

The Contractor shall work closely with the Government to determine the best use of time and resources to meet these needs if and when they arise.

(U) Security Requirements (U//FOUO) Contractor shall provide employees that are U.S. Citizen, all employees shall have and maintain an active TOP SECRET clearance. All OTD contractors are required to undergo polygraph examinations for positions on this Task Order. The FBI will be the final adjudicator for all access authorization. The FBI Security Office will not accept an Interim level clearance. Contractor personnel provided shall be subject to routine criminal and credit checks by the FBI.

(U) Travel and Other Direct Costs

(U) This requirement may require Other Direct Costs (ODCs) and travel. When required, ODCs and Travel must be pre-approved (in writing). When required and authorized, all travel must be pre-approved in writing and conducted in accordance with Federal Travel Regulations established by the General Services Administration.