Introducing the lightweight
F-35 Advanced Travel Pod.
KIHOMAC's carbon fiber aerial pod has been released from prototyping into production availability.
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The vertical stabilizer skin panel is a complex honeycomb-bonded structure made up of Nomex Honeycomb, aluminum skins and fiberglass skins. The weight and strength of the v-stab panel are important due to the weight and balance issues and to survive combat battle damage. Producing new v-stab panels with the exact specifications of the originals was a challenge, and critically important since there were no longer any spare parts to pull from for the panel.
A number of obstacles prevented other engineering firms from completing the refurbishment process. V-stab panels are complex structures with tight tolerances, built from a combination of Nomex Honeycomb, fiberglass, and extremely thin chemically milled aluminum skins. Being able to control weight with a structure of this size is a challenge, and yet we felt confident in our ability to find a solution.
Working on a project this large requires experts. We brought in our top engineers and spent weeks analyzing old parts, original drawings and specification sheets in order to come up with a working methodology. The procedures to build v-stab panels didn’t exist anymore — until we recreated them — which meant there weren’t any step-by-step guides we could follow to take us through the process.
Based on the methodology and manufacturing steps developed, we were able to create our own composite tooling — called bond forms — designed and manufactured by KIHOMAC at our Center for Advanced Manufacturing in Layton, UT.
CloseA rash of F-22 landing gear malfunctions created safety concerns for the F-22 fleet during a period of heightened tensions in the Middle East. To resolve these MLG anomalies, Lockheed Martin designed a brace preventing over-center conditions in the F-22 MLG. This brace fits inside the confined space of the main landing gear bay, integrates with the existing structure and is subject to robust cycle requirements. These braces are secured by fracture-critical pins. All these requirements drove a complex geometry with exacting tolerances. Due to the impact on fleet readiness, Lockheed Martin needed the full complement of braces and pins delivered in 16 weeks.
Lockheed Martin selected KIHOMAC to rapidly manufacture the F-22 MLG brace and pins. The specified material is a proprietary high-strength stainless steel. KIHOMAC secured the unique alloy from several vendors around the US. Working closely with the F-22 team at Hill AFB, KIHOMAC validated the geometry and fit of our prototype. This aggressive procurement strategy and customer engagement helped expedite First Article acceptance and enabled KIHOMAC to deliver all braces and pins on time. These assemblies are now installed on every F-22, ensuring the safety and availability of these vital national assets.
CloseThe two WC-135 aircraft orignally outfitted for the Open Skies treaty were equipped with a wet film system repurposed from 1970’s era reconnaissance cameras. As wet film moved into obsolescence and digital capabilities increased, the need to update the system became increasingly apparent, driving the Air Force to open a contract for the development of an updated camera system and supporting infrastructure.
As the Prime Contractor, KIHOMAC was responsible for the development of the $36.6 million dollar Digital Visual Imaging System (titled as DVIS). Requirements included a new, integrated Open Skies mission suite with digital imaging, real time mission management and ground processing.
KIHOMAC developed, manufactured and installed this system, moving from clean sheet design to first installation in just 22 months. The Air Force approved Milestone C in May 2020, indicating development was complete and the system is now ready for Operational Testing and Treaty Certification.
CloseThe bane of an Air Force Maintenance technician’s existence is a “Retest OK” or RTOK. A radio failed in flight but checks out just fine on the ground -- that’s an RTOK. Over 40% of the time, the problem is related to the connector or the wire. The wire flexes during flight, and causes a component to stop working. How do you improve weapons availability with RTOKs?
To improve the availability of the C-5, the Air Force selected KIHOMAC to develop and implement a program to improve the reliability and availably of any component involving wiring. KIHOMAC today runs the C-5 Electrical Wiring and Interconnect System (EWIS) integrity program for the C-5 program office. At the request of the Air Force, we support the DOD level organization that categorizes leading wire and connector issues which helps bring the C-5 successes to the other services.
CloseKIHOMAC’s world-class engineering, manufacturing and quality teams have an exceptional record of providing Critical Safety Item (CSI) and Flight Control Surfaces. KIHOMAC currently produces CSI/Flight Control Surfaces for the A-10, E-2, and F-16. KIHOMAC has a 100% acceptance rate on deliveries of 365 A-10 Rudder Trailing Edges, 320 A-10 Universal Rudders, 70 E-2 Flap Trailing Edges, and 130 F-16 Horizontal & Vertical Stabilator Skins.
B-1 bombers unable to fly and carry out its mission, all because of the lack of a critical part, a B-1 Impeller for its electronic warfare system. The Air Force and Defense Logistics Agency sustainment teams contacted the OEM and was told that this would take 3 years to deliver. The team was able to meet the immediate need by pulling an old part out of the Aircraft Maintenance and Regeneration Group. But for the solution, the Air Force turned to KIHOMAC for a more rapid response.
The challenge was that the Impeller had precise tolerances – some as tight as +/- 0.0001 inches. We reversed engineered the entire manufacturing process, from high precision machining, critical testing, and improved metal treatment processes. We developed a 3D CAD model and validated the new data. We programmed our computer-aided manufacturing mills to precisely shape the raw metal. We then conducted spin testing, at 21,000 RPM, to assure a perfect part. We delivered and passed the first article within one week after contract award, and went on to deliver 40 production units within 4 months. We have subsequently produced 220 units to date.
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