Production and Qualification Testing of B-52 SAS Toggle Switch

Mainstream is concluding a successful Phase I in which a functional B-52 toggle switch prototype was designed, fabricated, and functionally tested.  Mainstream has leveraged a unique combination of reverse engineering and manufacturing to develop a form, fit, and function replacement for NSN 5930-01-563-8334, a specialized double-pole double-throw (DPDT) toggle switch used in the Stability Augmentation Subsystem (SAS) on the B-52.  The toggle switch was discontinued by the original manufacturer with no direct replacement, requiring USAF to acquire used switches from their boneyard and necessitating the need for an additional source of supply. Mainstream developed a method to produce replacement switches using modified COTS components.  During Phase I, prototype toggle switches were fabricated via this method and preliminary functional tests were performed.  Phase II will focus on qualification testing in accordance with an abridged version of Boeing’s Source Control Document 10-30398 as well as ground testing by the engineering support activity (ESA). DLA has determined that successful ground testing and qualification testing will suffice for source approval as a “preferred spare.”