TYNDALL AIR FORCE BASE, Fla. -- The 53rd Test Support Squadron’s Advanced Threat Development flight and Special Devices flight are saving the Air Force more than $700,000 through collaboration and innovation.
Together, the flights modified new jamming pods, which emit radar-blocking electronic signals, for approximately $53,000 in materials and supplies, whereas it would have cost approximately $765,000 to contract the work.
Modernizing jamming techniques is at the heart of the advanced threat development flight’s mission. In partnership with the special devices flight, the 82nd Aerial Targets Squadron and the U.S. Navy at Point Mugu, California, this unit maintains vigilance against global electronic warfare adversaries.
In November 2016, the advanced threat development flight received the newly advanced Filthy Buzzard jamming pods. The flight quickly recognized these pods required modifications before they could be incorporated into the QF-16 and BQM-167 systems operated by the 53rd Weapons Evaluation Group.
To accomplish these modifications, they reached out for assistance to the special devices flight. These Airmen took initiative and built new jamming pod sub-components for both the QF-16 and the BQM-167, saving the squadron from needing to outsource this requirement.
“Our Airmen are innovators. They see things differently,” said Capt. Joe Blanton, 53rd TSS Special Devices flight commander. “Fabricating the various parts and pieces required to adapt the Filthy Buzzard technology to the pod shells was both challenging and rewarding for our team.”
The flight’s innovative modifications were completed in January, six months ahead of schedule, with significant cost savings.
“Using the special devices flight reduced cost by 10 times compared to standard USAF and Navy contracting options,” said Andy Kay, Advanced Threat Development flight electronic engineer. “This was not only an incredible achievement compared to typical options, but it was an incredible display of how our flights work together to apply best ideas and improve operations.”
In addition, the Navy-run airborne threat simulation office at Point Mugu, analyzed the work done by the special devices flight, and highlighted the superior quality of their in-house, modified pods when compared to their contracted, manufactured peers.
Historically, the airborne threat simulation office returns a percentage of parts sent to them because of a failure to meet specifications. The special devices flight fabricated pods maintained a zero percent rejection rate.
According to Darin Williams, special devices flight lead machinist, the flight incorporated all aspects of fabrication for the pods to include: manual machining, computer numerical control milling and turning, waterjet operations, manual and CNC bending, 3-D machining, and fourth-axis work.
“Our Airmen have demonstrated a lot of enthusiasm utilizing their professional skill-sets on these projects,” said Williams. “Fabricating these parts put our Airmen on the cutting edge of air-to-air weapons evaluation.”