OCTOBER 202419MANUFACTURING TECHNOLOGY INSIGHTStesting, and evaluating advanced prototypes to modernize and enhance the mission range of future ground support equipment and vehicles. The prototype examples included the hybridization of legacy diesel-powered ground support equipment and vehicles and the development of advanced power and lighting systems and battery-powered flight line generators and light carts. These were incorporated with advanced lithium-ion batteries, silicon carbide power converters, power electronics and thermal management equipment, and high-efficiency LEDs. After completing a suite of validation testing, the prototypes were sent to an Air Force Test Wing for demonstration. The Air Force personnel analyzed the prototypes and provided feedback. This opened opportunities for potential features, capabilities, and airmen safety for next-generation flight line equipment, resulting in a lighter, more efficient, and more flexible power fleet. CTC also explored opportunities to improve system efficiency with advanced technologies, enable multi-capable equipment, strengthen posture for an electric future, and enhance airmen's work conditions. In another recent success story, CTC helped an Army client who required a lightweight, small-caliber cartridge case. To adapt to the small caliber cartridge case manufacturing, it connected advanced manufacturing techniques from adjacent industry areas with advanced modeling and simulation. This solution met the weight savings and drop-in functionality requirements, ensuring reduced fuel and transportation costs from cartridge weight savings. The CTC design also facilitated firing range cleanup due to the cases being magnetic. Created using metal injection molding, this single-piece, high-strength metallic cartridge case is stronger, stiffer, and lighter than traditional brass. The shell case design was so innovative and unique that it was awarded a patent. These cases are reloadable for consumers and competitive shooting as well."We have driven many similar successes and achievements by conducting design reviews with clients and inviting stakeholders and users to provide feedback to ensure varying perspectives," says Denault.CTC takes pride in developing meaningful relationships with clients and fully understanding their requirements to support their mission. "We believe nobody understands real-world requirements better than end users, especially in the defense space, and encourage stakeholder participation in the design, test, and evaluation phases," says Shawn Rhodes, CTC mechanical engineer. "We pay attention to their perspectives and incorporate their inputs into the solution."This outreach approach has proven valuable for CTC as it creates a sense of ownership in clients. End users appreciate that their feedback from prototype field-testing is incorporated in the final product. CTC values its employees and provides an environment where technical experts, program managers, and business staff collaborate to provide robust, cost-effective solutions for clients. CTC's engineers, scientific experts, technicians, and program managers have in-depth experience in materials, design, analysis, rapid prototyping, testing, and manufacturing. Many of the company's team members are retired military personnel and reservists, who contribute unique expertise.CTC has supported DoD clients for more than three decades, providing innovative yet effective techniques and a design-to-production holistic approach. Remarkably, the National Armaments Consortium (NAC) and the DoD Ordnance Technology Consortium have recognized CTC for outstanding technical achievement in its groundbreaking engineering, manufacturing, and production processes.CTC continues to employ a customer-focused approach as it grows to ensure its capabilities, staff, and investments are aligned with client missions. It strives to develop advanced systems and manufacturing technologies in its 400,000 square feet site in Pennsylvania with small-caliber ammunition prototyping labs, large-scale electro-mechanical system prototyping areas, and research and development facilities. Our expertise in materials and advanced manufacturing technologies allow us to meet client requirements in novel ways
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