APSD-D-4284-CapabilitiesBrief.pdf

APSD-D-4284 Rev C

Aircraft Prototype Systems Division

CAPABILITIES BRIEF

FY22

Presented by: APSD Chief Engineer

NAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

About Us 3 Requirements Collection 11

Benefits of UtilizingAPSD 4 Project Management 12

QualityManagement 5 Design 13

History 6 Analysis 18

Our Customers 7 Procurement &

Staffingand Personnel 8

Scope of Work 9

Where We Fit 10

Table of Contents

Contracting 21

Fabrication/Installation 23

QualityControl 29

Post Delivery Support 31

Inquiries 33

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

MISSION:

The Aircraft Prototype Systems Division (APSD) provides engineering, manufacturing and contract services that rapidly deliver quality airworthy designs, components, modifications, and installations to close emergent airborne capability gaps.

About Us

APSD translates customer requirements into products.

Project Management

Design Procurement Fabrication Installation

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Benefits of Utilizing APSD

APSD Products

• Government owned technical data packages (TDP’s) to document products

APSD Personnel

• Leverage in-house skillsets as well as resources across NAWCAD and NAVAIR

• Existing relationships with NAVAIR airworthiness SME’s and familiarity with the process

• Additional resources available through contract vehicles

APSD Can Provide Immediate Execution and Support

• Able to respond quickly to urgent needs using in-house capabilities

• Flexible Government to Government work agreements

• Processes to quickly adjust to schedule and requirements changes

• Multiple quick turn contract options for additional capabilities and surge capacity

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Quality Management

• AS9100D Certified Quality Management System (QMS)

• Process Oriented for traceability, uniformity, and repeatability

• Processes to guide leadership, planning, design, development, configuration management, and more

• Ground operations, modification, and installation processes audited by the Aviation Maintenance

Management Team (AMMT)

• All project documentation maintained under configuration management (CM) control

• All Aircraft ground operations, modification, & installation procedures codified with NAVAIR Aircraft Controlling

Custodian Office

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

History Established in the Test and Modification Community . . .

60+ years of service to the

Naval Aviation Enterprise

Roots in early NADC Aircraft

Modification and NATC

Flight Test Support, which merged in 2004 to create the current division

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Customers/Partners

PMA 201 PMA 234 PMA 264 PMA 274

PMA 202 PMA 242 PMA 265 PMA 275

PMA 205 PMA 257 PMA 266 PMA 276

PMA 207 PMA 260 PMA 268 PMA 281

PMA 209 PMA 261 PMA 271 PMA 290

PMA 226 PMA 262 PMA 272 PMA 299

PMA 231 PMA 263 PMA 273 PMA 290E

PARTNERSPMA CUSTOMERS

• Airborne

Instrumentation

Division (AID)

• AIRWorks

• Rapid Prototyping

Experimentation

Division (RPED)

• Cargo Special Ops Lab

APSD-D-4284 Rev C

• Office of Naval

Research (ONR)

• Air Force Research

Laboratory (AFRL)

• Johns Hopkins

University Applied

Physics Laboratory

(JHU/APL)

NAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Staffing & Personnel

150+ Team Members

Functional Areas

• Staff

• Production

• Quality Assurance

• Acquisition

• Operations

• Engineering

8APSD-D-4284 Rev C

Staff

Production

QA

Acquisition

Operations

Engineering

NAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Scope of Work

• AcquisitionAlternatives

• Comm/Nav System of System Upgrades

• Mission System Integration

• Weapon Systems Integration

1w 1m 6m 1y

5y

Multi System Modifications

• Technology Demonstration Pods

• Aircraft System Integration Designs

• OEM Alternative Components

• Alternative Capability Designs

• S&T Product Ruggedization

1m1w 6m 1y

5y

Prototype Development

1w 1m 6m 1y 5y

Limited Scale Modifications

• Regulatory compliance system upgrade - ADS-B Out, RNP R-NAV

• Single System Upgrades

• Rapid Response Projects

• Urgent/Emerging Need Statement Solutions

• Fleet Experimentation

• Technology Demonstrations

1m1w 6m 1y

5y

Non-Traditional Support

• Equipment Racks

• Wiring Harnesses

• Build to Print Fabrication

• Obsolete Part Replication

1m1w 6m 1y

5y

Products and Parts

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Where We Fit

Systems

Engineering

APSD

Operational

Need Delivered

Capability

Requirements Validated

Solution

Design Product

Systems Engineering Process

DT&E

OT&E

IOC / FOC

Design Product Project Management from

Design to Product

CAD, Drafting, and Analysis

Quality

Inspection

Implementation

Machining, Fabrication, Wiring, Kitting and

Installation

Procurement &

Contracting

Post Delivery

Support

APSD Activities

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Requirements

Programmatic

• Cost

• Schedule

• Risk

Technical

• Performance

• System Specs

• System Architecture

• Equipment

APSD assists the customer in the collection of project requirements.

Upon request APSD can augment the customer systems engineering staff with defining requirements.

PROJECT REQUIREMENTS

Airworthiness

• NAVAIR Instruction 13034.1 (Airworthiness)

• MIL-HDBK-516

• FAA Title 14 CFR parts 23, 25, 27, 29

Organizational / Statutory

• AS9100D

• DoD Instructions

• NAVAIR Instructions

• MIL-STD-31000

• ASME Y14.100

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Project Management

APSD Project Management is designed to efficiently interface with NAVAIR PMAs, IPT’s, and other customer program management teams.

Tailorable Project Management Products

• Project Status Reports

• Cost and Schedule Management

• Risk Management

• Real-time Requirement Changes

Tailorable Systems Engineering (SE) products

• Program Reviews

• Technical Interchange Meetings (TIMs)

• Systems Engineering Technical Reviews (SETR)

Financial Support Functions

• Business Financial Manager (BFM) and Comptroller Interfacing

Schedules

Risk Products

Status Reports

Spend Plans

Design Progress Tracking

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Design

APSD-D-4284 Rev C

• Design for Systems Integration

– Developmental+ Level Technical Data Packages

• Drawings, Logistical Products, Instructions Documents

– Reports

• Weight & Balance, Electrical Loads, ThermalAnalysis, etc

– Associated documentation for NAVAIR Flight Clearance approvals

• And other certification authorities (FAA)

• Reverse Engineering

• Conceptual Design Studies

• Ad Hoc Engineering Design Services

– Tailorable Deliverables, Iterative Design Approaches

(Tailorable to Specific Needs)

Production Level TDPsConceptual Design Studies Ad Hoc Services Developmental Level TDPs

Engineering Design Spectrum

NAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Design Tools

3D Model Based Design

• With 2D Manufacturing Drawings

Mechanical design tools

• PTC Creo CAD

Electrical design tools

• 2D Design AutoCAD 2019

• 3D Design CREO Schematics +

Parametric

Configuration Management tools

• PTC Windchill

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Design Deliverables

Tailorable products:

• Matching platform conventions

• Different diagram styles

• Flexible reference designator schema

Technical Data Packages

• MIL-STD-31000 Tailored Developmental Level

• ASME Y14.100 Based Drawing Packages

• 2D Drawings and 3D Models

Airworthiness Reports

• Structural Analysis

• Thermal Analysis

• Modal Analysis

• Delta Electrical Loads Analysis (ELA)

• Delta Weight and Balance

Project Documentation

• Photo Books

• Installation Instructions

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Concept

Technical

Drawing

Fabrication

Mechanical Part Lifecycle

Design

Analysis

Prototype

Installation

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Concept Analysis

Technical Drawing

Electrical Part Lifecycle

**TYPICAL CUSTOMER SUPPLIED

(BLOCK DIAGRAM)

Design

Prototype

Installation

Fabrication

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Analysis Tools

APSD Analysis group demonstrates the airworthiness and structural integrity of components for safety of flight certifications.

Tools Structural:ANSYS FEA (Finite Element Analysis) software

• Static and fatigue strength, aircraft interface loads

Dynamic: ANSYS modal FEA

• Natural frequencies, mode shapes

Thermal: ANSYS [Fluent] Icepak software

• Evaluate equipment / system integration survivability from introduced thermal loading

• Heat transfer, cooling

Aerodynamic: ANSYS Fluent software

• CFD (Computational Fluid Dynamics)

• Developing capability

Products

• StructuralAnalysis Reports

• StructuralAssessment Memos

KC-130J

Harvest

Hawk+ EO/IR

Turret modal

FEA

P-8A RFCM

POD FEA

Model

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

CH-53E ALE-47 Dual Chaff/Flare

Dispenser Pod Strain Gage

Instrumentation & Testing

Analysis Validation

Structural: Classical “hand” analyses; proof tests;

strain gage instrumentation and testing

• Original Equipment Manufacturer (OEM) handbooks, textbook hand calculation methodologies

• Cargo Lab test support

• Structures Lab instrumentation and test support

Dynamic: Siemens modal impact Resonance

Assessment Profile (RAP) testing

• Natural frequency, mode shape determination

MV-22B Display Proof Test

UH-72A Instrumentation Boom modal impact RAP TestBox Free Body Diagram for Hand Calculations Antenna Free Body Diagram for

Hand Calculations

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Reverse Engineering

APSD utilizes reverse engineering and digitization to support:

• Design and development- provides high accuracy scans of aircraft and other design interfaces

• Recreation of missing or unavailable engineering data

• Inspection of complex geometry

Faro Edge

Type: Touch probe and laser line scanner

Scan accuracy:

±0.0014 in

Artech Eva

Type: Structured light scanner

Scan accuracy:

±0.004 in

Supporting software:

• Geomagic Design X

• Faro CAM2

• Artec Studio

• Creo Parametric

E x a m p le

H U

D

O b s o le s c e n c e 1. Data Capture

APSD-D-4284 Rev C

2. Data refinement 3. CAD Model Creation 4. Drawing

Products:

• Design envelope CAD models

• Geometrically accurate CAD models

• Engineering manufacturing data-CAD models and drawings

TOOLS:

NAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Procurement

Procurement capabilities are Flexible and Broad Ranging

• Small - P-Card

• Medium - Rapid Acquisition Contract (RAC)

• Large - MultipleAward Contract (MAC)

Technically-Based Project Support

• Federal Supply System (MILSTRIP)

• Rapid Action Contract (RAC)

• Defense LogisticAgency (DLA)

• NASA SEWP

APSD Procurement

• Efforts Managed by APSD

• StandardizedAPSD Processes

• NAVAIR Standard Operating Procedures (SOPs)

• Template Documentation

• Standardized Processing Times

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Leveraging Industry

• APSD Acquisition – Provides the ability to augment a customers buying power

• Customer focused

• Streamlined acquisition

• Vendor risk assessments

• Vendor auditing

• Government Owned Data

Rights

• 10 U.S.C 2371(b) OTAs

• 10 U.S.C. 2373

Acquisitions

Extended Bandwidth ● Production ● System or Product Development

• APSD Prototyping and Limited Production (PLP) Multiple Award Contract (MAC)

• Prototype Air Vehicle Modifications

• Systems Development

• Integration and Installation Activities

• Limited Production Requirements

• APSD Compass C5ISR BOA

• JHU APL Task Orders

• NAWCAD Full Rate Production MAC

• Aircraft Components

• Systems & Modification Kits

• Other Procurement Vehicles

• Federal Supply System

• RAC

• DLA

• NASA SEWP

• P-Card

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Sheet Metal Fabrication/Assembly

In-House, On-Site Sheet Metal Fabrication and Assembly shop: Capable of full-range fabrication services, from simple flat plate cutout to complex forming and assembly operations.

Tools:

• 1 - CNC Waterjet Machining Center

• 2 - CNC Routers with Z Direction Travel

• 3+ - CNC Sheet Metal Press Brakes

Products:

• Formed Sheet Metal Components

• Mechanical Assemblies

• Switch Panels

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Machining

Computer Numerical Control Equipment:

• 2- Haas TM1 Tool Room Mill 30"x12"x16"

• 1- Haas TL2 Tool Room Lathe 8"x48"

• 1- Haas VF-2 Mill 30"x16"x20"

• 3- Haas VF-4 Mill 50"x20"x25"

• 1- Haas VF-5 Mill 50"x26"x25"

• 1- Haas VF-6 Mill 64”x32”x”30”

• 1- Haas VF-8 Mill 64"x40"x30"

• 2- Haas VF-9 Mill 84"x40"x30"

• 1- Haas UMC-1000SS 5-Axis Mill 40"x25"x25"

• 1 -Haas ST30Y Lathe 9.400"x4"x32.5"

• 1- ProtoTRAK Lathe

• 1- ONAAX3 Electrical Discharging Machining

(EDM)

Manual Equipment:

• 1- ProtoTrak Lathe LX3

• 4- ProtoTrak Mills

(1) DPM5, (3) K3

• 2- Bridgeport Mills

• 1- Harrison Lathe

• 2- Monarch Lathes

In-House, On-Site Machine Shop: Capable of full-range machining services, from one-off build-to-print parts to multi-kit prototype fabrications.

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Treating and Finishing

Heat Treating:

• 1 – Aluminum heat treat oven

• 1 – Steel heat treat oven

Metal Finishing:

• Chemical Conversion Coating

• Sulfuric AcidAnodizing

Painting :

• 2 - 8’x8’ paint booths

• 1 - 6’x6’ drying oven

• Epoxy Primer

• Polyurethane Topcoat

• Lacquer Topcoat

In-House, Finishing Services: Capable of metal finishing from heat treating, to plating and painting.

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Additive Manufacturing

APSD utilizes in-house polymer AM equipment to support:

• APSD design and development processes

• Component fabrication

• Fabrication for external customers.

ECS Ducting

Instrument Panel fit check

Products:

• Fit check components

• Equipment representations (i.e. ARC-210 shape)

• Manufacturing fixtures

• End use items

• For flight components

Fortus 450mc

Type: FDM

Build size:

16 x 14 x 16 in

Materials: ULTEM 9085, PC, ABS-M30, Nylon 12CF, etc.

Markforged x7

Type: FFF with continuous fiber reinforcement

Build size: 13 x 10.5 x 7.8 in

Materials: Onyx, various fiber reinforcement

TOOLS:

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Wiring

POWER / SIGNAL / ETHERNET / MORE

HARNESS FABRICATION AND KITTING

BOX-LEVEL WIRING RACK-LEVEL HARNESS ROUTING

APSD-D-4284 Rev C

In-House, On-Site Wiring Fabrication And Assembly Shop: Capable of full-range wiring services, from single conductor loose wire fabrication to multi branch cable assemblies to complex wired deliverables and aircraft.

Tools:

• Permanent Laser Marker Machine

• Shrink Label Machine

• Layout Tables

Products:

• Individual Wires

• Cable Assemblies

• WiredAssemblies

• Switch Boxes

• Power Distribution Boxes

• Wired Equipment Racks

• ModifiedAircraft Harness Routing and Installation

NAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Aircraft Installations & Modifications

SINGLE SYSTEM UPGRADESDEMONSTRATION SUPPORT

PROTOTYPE INTEGRATION MULTIPLE SYSTEM INTEGRATION

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Quality Control - Fabrication

Conformance

Inspections to ensure that products match airworthiness approved drawings

Conformance

Inspections to ensure that products match airworthiness approved drawings

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Quality Control - Installation

Aircraft Modification Form (AMF) to document modification authority, flight clearance, and sign-offs

Aircraft Modification Checkout Record (AMCR) to verify installed system configuration and document QC checks

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Post Delivery Support

• Product alteration to support flight test findings

(FLY-FIX-FLY)

• On Site Support of System

• Experienced troubleshooting and problem-solving support

• Experienced Engineers and Technicians familiar with varied aircraft systems

• Drawing package updates and design transfers

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

Scientific Development Squadron VXS-1

VXS-1 operates NP-3 Orion aircraft.

FY22 user Fee per Flight Hour, $16,000

(Non-NRL) $12,000 (NRL)

NP-3 Features include:

• Multiple nadir ports and one zenith ‘pyrotechnic’ port

• Ten wing mounting hard-points

• Tail cone radome

• Freefall sonobuoy/dropsonde chute

• Nose radome

• Bomb Bay Equipment Platform (BEP)

• Dedicated project power distribution system, network switch, GPS signal distribution

VXS-1 operates RC-12M aircraft.

FY22 user Fee per Flight Hour, $3,000

(Non-NRL) $1,800 (NRL)

RC-12M Features include:

• External belly mounting capability

• GPS signal feed

• Iridium antenna

• Dedicated power distribution system

• Optional fiberglass belly radome (110" x 53") can be configured with or without an optical window

VXS-1 operates UV-18 Twin Otter aircraft.

FY22 user Fee per Flight Hour, $2,000

(Non-NRL) $1,300 (NRL)

UV-18 Features include:

• Two bubble windows (port & starboard)

• Two zenith ports

• Nose compartment camera port/turret mount and smaller nadir port

• Large aft fuselage cutout (27.5” x 36”)

• Removable wing pylons

• Sonobuoy/dropsonde deployment chute

• Dedicated power distribution system

APSD has built a partnership with VXS-1, a local NAS Pax squadron charged with science and technology

(S&T) development efforts under the Office of Naval Research (ONR). VXS-1 operates multiple platforms that can demonstrate components and systems ahead of, or in lieu of formal acquisition programs.

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

INQUIRIES?

Please direct all potential project inquiries & questions to:

Facility Tours Encouraged

AIRCRAFT_PROTOTYPE@US. NAVY.MIL

APSD-D-4284 Rev CNAVAIR Public Release 2023-124. Distribution Statement A – Approved for public release; distribution unlimited.

mailto:AIRCRAFT_PROTOTYPE@NAVY.MIL