Electromagnetic Aircraft Launch System (EMALS

The Electromagnetic Aircraft Launch System (EMALS) program is a major Navy initiative funded under Budget Line Item (BLI) 4219, within the Other Procurement, Navy appropriation. EMALS is designed to replace the legacy C13 Steam Catapult System aboard Ford Class aircraft carriers, with the primary goal of providing an advanced technology launch system that improves reliability, maintainability, and operational availability. The program supports both procurement and life cycle modifications, ensuring the system remains effective throughout its operational life. EMALS is currently installed on CVN-78 and at a land-based System Functional Demonstration (SFD) site.

A key objective of the EMALS program is to address system obsolescence and enhance performance through Engineering Change Proposals (ECPs). These modifications target critical or obsolete parts, reliability improvements, operational capability upgrades, and safety enhancements. The budget supports upgrades such as Transformer Rectifier (T/R) Fuse Detection, Motor Controller improvements, Block Switch Sensor (BSS) safety software, and Prime Power Interface Subsystem (PPIS) inverter software. These ECPs are prioritized based on fleet requirements and findings from operational testing, ensuring EMALS can support evolving mission needs and maintain safety standards.

Another major goal is the standup of depot-level repair capabilities for Ford Class carriers. Funding supports the procurement of logistics products, on-equipment tooling, test fixtures, test stands, and OEM-manufactured tooling necessary for planned overhaul cycles. The program also invests in Detailed Functional Description Data Packages (DFDDPs) to facilitate the design and procurement of future test benches, which will enhance high- and low-power testing, troubleshooting, and fault diagnostics for EMALS components. These efforts are crucial for establishing the capacity to support four Ford Class ships by 2028.

The Production Engineering (PE) and Integrated Logistics Support (ILS) components of the budget are tailored to support ongoing ECP efforts and depot standup activities. PE funding ensures that technical documentation, installation hardware, and drawings are up to date, while ILS funding addresses the complexity of logistics elements required for each modification. Year-to-year funding levels for these activities fluctuate based on the mix and complexity of ECPs, as well as the evolving needs of the fleet. This approach allows the program to remain agile and responsive to urgent operational requirements.

The Support Equipment line item funds the expansion of EMALS depot and Software Support Activity (SSA) capabilities. This includes minor improvements and capability expansions for the EMALS lab, which are necessary to support ongoing software updates and cyber compliance mandates. The SSA ensures that EMALS software remains secure and functional, addressing any issues that arise under normal operating conditions. These investments are aligned with broader Department of Defense policies on efficiency and cost-effectiveness, as evidenced by a reduction in advisory and assistance services in accordance with Executive Order 14222.

Installation activities for EMALS modifications, such as T/R Fuse Detection and Motor Controller upgrades, are scheduled during Pier Side Ship availabilities. The cost and timing of these installations depend on ship availability, location, and baseline configuration. Production lead times include pre-installation checkout, hardware kitting, and delivery to the installation site. Manufacturers such as General Atomics play a key role in producing and delivering these components, with administrative and production lead times carefully managed to align with Navy schedules.