Reverse Engineering Equipment Open Topic

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Advanced Materials, Trusted AI and Autonomy, Integrated Network Systems of Systems, Microelectronics

OBJECTIVE: As equipment ages and global events interrupt critical supply chains quickly, creating solutions for components that integrate well without impacting system performance is necessary. This topic aims to source and develop robust, versatile, and cyber-secure technologies that can be utilized for this task. The objective is to leverage innovations that ensure operational readiness and effectiveness in diverse and resource-constrained settings. Such technological advancements will fortify military readiness and potentially influence civilian sectors where infrastructure is limited. By cultivating a suite of technologies that are as autonomous as they are resilient, the focus shifts to maintaining superiority in operational logistics and sustainability, setting new standards for reverse engineering to eliminate obsolete or vulnerable parts. Systems that the depot engineers might need to reverse engineer include cables, components of wires, circuit cards, mechanical elements, bench and line repairable units, and chassis.

DESCRIPTION: This topic accepts Phase I proposals submissions for a cost up to $250,000 for a 6–12-month period of performance.

This solicitation seeks innovative proposals to develop a comprehensive reverse engineering suite of tools that significantly enhances the capability to replace, augment, and improve components in military and civilian systems. The proposed suite should focus on the following advanced research areas:

• Precision Scanning and Modeling Technologies: Develop advanced scanning technologies capable of capturing micro-level details of complex components. Research should explore novel methods for converting physical scans into highly accurate parametric models, including machine learning algorithms to improve scan accuracy and model fidelity.
• Integrated Design and Engineering Platform: Propose the creation of a unified platform that seamlessly integrates technical drawings, engineering data, and user annotations. This platform should facilitate the easy addition of detailed specifications, such as materials, dimensional tolerances, and mechanical properties, enhancing the capability to produce deployable designs quickly.
• Multi-Parameter Simulation Environments: Advance the development of simulation tools that can model mechanical, electrical, and thermal behaviors of components within a system. Research should focus on creating simulations that can predict the performance of redesigned parts under various operational conditions, thereby validating their efficacy before physical production.
• Autonomous Design Optimization: Investigate autonomous systems that utilize artificial intelligence to suggest improvements in component designs based on historical data and performance metrics. This includes autonomously generating alternative designs that enhance performance, reduce costs, or address material availability issues.
• Cyber-Secure Data Management: Develop robust security protocols for managing sensitive design and engineering data. Research should include the creation of secure data environments that protect against cyber threats while allowing seamless integration with existing CAD and product lifecycle management tools.

Each proposal should ensure that the tool suite can operate with high mobility and adaptability on both the production floor and in field settings. Proposals must address the suite’s ease of use, including detailed plans for user training and software licensing. The autonomy of the tools for end-users, specifically at the Letterkenny Army Depot (LEAD), should be emphasized, ensuring they can operate the suite independently without ongoing support from the contractor. The proposed solutions must prove their effectiveness in enhancing operational readiness and overcoming challenges posed by material obsolescence and supply chain vulnerabilities.

Benefits of partnering with LEAD: LEAD operates under 10 USC 2474 as a designated Center of Industrial and Technical Excellence for Air Defense & Tactical Missile Ground Support Equipment and Mobile Electric Power. This designation allows for establishing public-private partnerships that align with LEAD’s core competencies, as long as they do not interfere with National Defense Priority Programs. LEAD has ample production space to support various mechanical, electronic, and fabrication projects. The facility can handle everything from large trailer beds to intricate circuit card repairs and is equipped with sophisticated machinery such as multi-axis mills, water jets, and laser cutters. LEAD’s capabilities are broad, spanning automotive repairs, heavy metal fabrication, and more.

PHASE I:

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.

Studies should clearly 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.

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:

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:

Complete the maturation of the company’s technology developed in Phase II to TRL 6/7 and produce prototypes to support further development and commercialization. The Army will evaluate each product in a realistic field environment and provide small solutions to stakeholders for evaluation. Based on Soldier field assessments, companies will update the previously delivered prototypes to meet the final design configuration.

Disaster relief operations, field construction in rural or undeveloped areas, forestry and agricultural heavy lifting, emergency medical setups in disaster zones, off-grid construction projects, wildlife research and conservation efforts, archaeological digs in remote locations, search and rescue missions, oil and gas exploration in isolated areas, humanitarian aid delivery in conflict or disaster-stricken regions.

Other Use Cases:

• Lightweight or Wearable Ruggedized Scanning Technology: Easy-to-use, light-weight, ruggedized scanning technology capable of providing detailed scans for large or small discrete components or systems. Solutions should provide a rapid processing speed with enough memory to store output from multiple scans and the ability to download and transmit securely. 
• Integration Digital Design Suite:  Allows scans to be integrated within technical data packages and system simulation.
• Shared Engineering Drawing board:  Allows a shared common operating picture for artisans and engineers to exchange information securely in both the physical world and share technical data securely. Subject Matter Experts in remote, dispersed locations should be able to see real time faults, overlay technical prints to provide troubleshooting options and redesign details and simulation results.

REFERENCES:

1. Advances in Design, Simulation and Manufacturing IV
2. Geometric Variability in Parametric 3D Models: Implications for Engineering Design
3. Design Oracle for AI-Based CPS Design
4. Design Engineering in the Age of Industry 4.0
5. Deep Reinforcement Learning for Multi-Phase Microstructure Design
6. A scalable digital platform for the use of digital twins in additive manufacturing
7. REARM keeps aircraft flying > Air Force Life Cycle Management Center > Article Display
8. Knowing how to REACT > Tinker Air Force Base > Article Display (af.mil)
9. Reverse Engineering of Mechanical Parts: Resolving Component Obsolescence | Advanced PCB Design Blog (cadence.com)

KEYWORDS: Deployable tools, field lifting devices, remote operations, energy efficiency, limited power access, minimal internet connectivity, durability, adaptability, extreme conditions, military operations, operational capabilities, logistical support, strategic advantage, resource-scarce locations, manual operation, solar power integration, hand-powered devices, autonomous lifting solutions, portable equipment, environmental resilience.