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Volume 2: Technical Volume TF34 Fuel Cooled Oil Cooler (NSN:2935010370494/160064-1-1) Small Business based Supply Chain Development

Award Information
Agency: Department of Defense
Branch: Defense Logistics Agency
Contract: SP4701-21-P-0032
Agency Tracking Number: L202-001-0234
Amount: $100,000.00
Phase: Phase I
Program: SBIR
Solicitation Topic Code: DLA202-001
Solicitation Number: 20.2
Timeline
Solicitation Year: 2020
Award Year: 2021
Award Start Date (Proposal Award Date): 2020-12-08
Award End Date (Contract End Date): 2021-04-08
Small Business Information
821 N Nash Street
El Segundo, CA 90245-1111
United States
DUNS: 079962012
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Derek Smith
 dsmith15
 (310) 607-0188
 derek.smith@morf3d.com
Business Contact
 Ivan Madera
Phone: (310) 607-0188
Email: ivan@morf3d.com
Research Institution
N/A
Abstract

On the America Makes Maturation of Additive Manufacturing for Low Cost Sustainment Phase 2 (MAMLS Phase 2), UDRI and partners discovered that the TF34 Fuel Cooled Oil Cooler (NSN: 2935010370494/160064-1-1) has seen drastic increases in purchase price and lead time for the Defense Logistics Agency (DLA) in recent history. On that program, UDRI developed a hybrid manufacturing approach to FCOC production which leverages Additive Manufacturing (AM) in conjunction with traditional manufacturing techniques to lower manufacturing cost and lead time. This development was prompted by the challenges associated with non-destructive inspection and powder removal of fully AM heat exchangers. By approaching the manufacture of FCOC heat exchangers with a process agnostic mindset, it can be seen that, in low-volume, sustainment applications, AM is best utlized for replacement of costly castings. The remaining components can be produced with high quality and low cost through traditional means. As seen in Figure 1, inspection and powder removal of the printed components becomes trivial because full line-of-sight access is granted.             Transitioning that research into commercialization, Morf3D, in partnership with UDRI, Honeywell, and Macy Consulting, are proposing the establishment of a small business supply chain which will  manufacture replacement TF34 FCOCs for the DLA leveraging the existing Technology Data Package (TDP) from Honeywell, under a licensing agreement, with modifications for the hybrid manufacturing process to be co-developed by Morf3D, UDRI and Honeywell.             This small business supply chain will provide problematic parts to the DLA with decreases in cost and lead time. This supply chain will forge a new pathway for the development and supply of many hard to source NSN parts. Additionally, this effort will successfully transition technologies developed on previous AFRL and DLA funded efforts. By partnering with Honeywell, and licensing existing TDP data and proven process specification, the threshold for the qualification of this part can be drastically reduced, substantially lowering the risk of a successful outcome and full transition to the program of record (A-10).

* Information listed above is at the time of submission. *

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