Advanced Manufacturing of Engine Cooling Fans for Wheeled Vehicles

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Advanced Infrastructure & Advanced Manufacturing; Advanced Materials OBJECTIVE: The Army (DOD, allies, and partner nations) lack a common understanding of the necessary components (technology and/or software) needed to resource an expeditionary Advanced Manufacturing capability capable of ad hoc design, fabrication, data transfer, assembly, quality assurance to fabricate complex Class IX repair parts. The Army seeks a solution to enable different Advanced Manufacturing (AdvM) technologies to work seamlessly, from item design through the fabrication of individual sub-components to assemblage of assemblies operated by Soldiers in tactical environments to fabricate complex Class IX repair parts. DESCRIPTION: This topic focuses on developing an advanced manufacturing solution for producing engine cooling fans for wheeled vehicles, utilizing a seamless integration of various AdvM technologies. This solution must enable ad hoc design, fabrication, data transfer, assembly, and quality assurance processes to produce multi-material Class IX repair parts in tactical environments. This project's scope includes leveraging novel technologies in additive manufacturing, CNC machining, and automated assembly to create a robust manufacturing system. Proposals should demonstrate a clear understanding of the operational challenges and outline a comprehensive approach to integrate multiple AdvM technologies into a cohesive system that soldiers can operate with minimal training. Additionally, the solution should include support resources such as technical manuals, training programs, and novel assistance capabilities to ensure successful deployment and operation in diverse environments. PHASE I: This topic is only accepting Phase I proposals for a cost up to $250,000 for a 6-month period of performance. 1. Companies will complete a feasibility study demonstrating the firm's competitive technical advantage relative to other commercial products (if other products exist) and develop concept plans for how the company's technology addresses Army modernization priority areas. 2. Studies should detail and identify a firm's technology at both the individual component and system levels, provide supporting literature for technical feasibility, highlight existing performance data, showcase the technology's application opportunities to a broad base of customers outside the defense space, a market strategy for the commercial space, how the technology directly addresses the Army's modernization area as well as include a technology development roadmap to demonstrate scientific and engineering viability. 3. At the end of Phase I, the Army will require the company to provide a concept demonstration of their technology to demonstrate a high probability that continued design and development will result in a Phase II mature product. PHASE II: 1. Produce prototype solutions that Soldiers can easily operate. Firms will provide these products to select Army units for further evaluation by the Soldiers. In addition, companies will offer technology transition and commercialization plans for the Department of Defense and commercial markets. PHASE III DUAL USE APPLICATIONS: Per research and current use cases, AM producers leverage 3D printing, computer-aided design (CAD), robotics, and smart manufacturing & industry 4.0 (SMI) to produce automotive parts CAD is the process of leveraging digital 3D models that detail the parts dimensions, shape, and more. It's a top use case for how data is used in AM. SMI is a concept which leverages various advanced sensors, IoT devices, and real Aside from CAD and SMI, AM, for auto part development, leverages data to create efficiencies in design and process as well as enable modeling & simulation processes to ensure the AM process succeeds. Materials used in AM are lightweight materials, generally polymers and carbon fiber reinforced polymers, which also have a crucial role in the technological competition between the U.S. and China, specifically as they relate to AM for drones and AM at the edge. Potential dual use cases for IR refractory testing techniques include: Industrial industries (e.g., HVACs, etc.) Space industry and reusable rockets/satellites Healthcare industry, specifically health tech products REFERENCES: 1. https://www.bing.com/ck/a?!&&p=cb5c6f0a502efe14JmltdHM9MTcyNDI4NDgwMCZpZ3VpZD0wY2VlOTUyYS0wMTM1LTY0NWUtMjQ5Yi04MWM5MDBjNTY1NjkmaW5zaWQ9NTIyNQ&ptn=3&ver=2&hsh=3&fclid=0cee952a-0135-645e-249b-81c900c56569&psq=sustaining+army+2023&u=a1aHR0cHM6Ly9jYXNjb20uYXJteS5taWwvYXNycC9idWlsZC9maWxlcy9TdXN0YWluaW5nJTIwQXJteSUyMDIwMzBfV2hpdGUlMjBQYXBlcl8wMSUyME9jdCUyMDIwMjNfRmluYWwucGRm&ntb=1 2. https://g2webcontent.z2.web.core.usgovcloudapi.net/OEE/Story%20Posts/TRADOCG2_2024JUL30_OE_2024_2035_Lg_Scale_Comb_anonymous.pdf 3. https://dsiac.org/articles/manufacturing-at-the-point-of-need-using-recycled-reclaimed-and-or-indigenous-materials/ KEYWORDS: Advanced, Manufacturing, AdvM, Design, Tactial, Fabrication