TechSolutions Helps Deliver Solution to Warfighter within Two Months of Request

As the lead of curriculum for the Naval Aviation Maintenance Center for Excellence Training (NAMCE-T) unit at Naval Base Ventura County (NBVC), Point Mugu, California, Master Chief Avionics Technician Andy Karsten wanted to give his students more than just PowerPoint instruction. He wanted them to get a feel for the parts of the plane they were going to be tasked with repairing – the E-2D Advanced Hawkeye. However, obtaining parts for that hands-on experience was going to be a challenge.

Karsten reached out to TechSolutions and asked, if there was a way to potentially obtain a 3D printer or connect him to somebody who could provide 3D printing services.

TechSolutions is the Department of the Navy’s (DoN) rapid response program that addresses warfighter needs by quickly developing science and technology-driven solutions. Although the request was out of scope for the program, which does not facilitate getting commercially available products, TechSolutions took immediate action to help. Dr. Scott Steward, then-deputy director of TechSolutions, connected with colleagues in their network to find someone who may be able to support the warfighter’s request.

The 3D printer would solve a huge issue for Karsten and his team of instructors. All of the E-2D Advanced Hawkeyes are operational with no additional spare parts to help train students. But with a 3D printer, Karsten said, they could manufacture their own.

“Our philosophy is 30% classroom and 70% doing hands on, interacting with either an aircraft or a device that accurately represents the aircraft,” Karsten said. “Rather than me telling them how it’s done, they’re able to do it.”

For example, Karsten said, the control yokes on the E-2Ds would be a challenge to teach how to repair without students physically handling it.

“There are buttons that are built into our control yokes on the airplane, and they are difficult to change when they're broken. Getting that part can be a challenge, so that would be something we would want to print,” Karsten said. “Not for use on an airplane, but in the classroom environment...so that students can practice outside the airplane on how to repair those components.”

Within two months of reaching out to TechSolutions through the Navy portal, Karsten said he received news that an out-of-use 3D printer was on its way to NBVC Point Mugu.

TechSolutions’ mandate is to create new, technology-driven prototypes to help Sailors and Marines accomplish their mission. In this case, however, since the technology already existed, TechSolutions put its communications skills to work, forwarding the request to other naval departments.

John "JC" Coffey , technical specialist, TechSolutions, said that his office recognized the value of Karsten’s request and expects the concept to eventually spread to other training divisions.

“Whether it’s for a ship, aircraft squadron or the International Space Station, in aviation we have to get approval for our parts from an approved parts list,” Coffey said. “The master chief and chief are pioneers in the application of using a 3D printer. So big bravos to them. They are on to the wave of the future.”

Not only does the 3D printer make the instructors’ job easier, Aviation Electrician’s Mate, Chief Petty Officer Shawn Myers, said he expects it to drastically improve qualifications for the command overall.

“When you get sailors that come in, it might take them seven months to qualify on certain specific jobs,” Myers said. “But here at NAMCE-T, we can knock it out in a much shorter time. They can come over here and instead of having to do five repetitions over five months, we can do five repetitions in two weeks or a week.”

While TechSolutions initially received the request for a 3D printer, Coffey emphasizes they had help in facilitating the request, including Cindy Waters , who is a senior science technology manager at the Naval Surface Warfare Center Carderock Division (NSWCCD) , and the Port Hueneme research and development group.

“Our mission is to link warfighters to the science and technology communities that can come up with solutions to the immense challenges our Sailors and Marines face – on the sea, in the air, in space and even in the classroom,” said Jason Payne, director, TechSolutions. “We welcome ideas and suggestions from all ranks and divisions within the Navy and Marine Corps. And if the solution doesn’t call for prototyping new technology, we’ll leverage our network to get to an existing solution.”

Sailors and Marines interested in learning more about TechSolutions may email the team at ONR_TechSolutions@navy.mil.