Engineering Edge: May 2013

The Engineering Edge

Edgewood Chemical Biological Center

Volume 5, Issue 5

May 2013

Military Appreciation Month

To access the electronic version of this newsletter, visit: http://www.ecbc.army.mil/news/ENG/ APPROVED FOR PUBLIC RELEASE

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Inside This Month’s Issue:

Awareness: Asian American and Pacific Islander Heritage Month

pg.3|ECBC Engineers Overcome Time Restraints and Challenges to Field LVOSS Abroad

In the United States, May commemorates “Asian American and Pacific Islander Heritage Month,” which is a time where the culture, traditions and history of AsianAmerican and Pacific Islanders are honored. In 1978 Congress passed a Joint Congressional Resolution to observe Asian/Pacific American Heritage Week in the first week of May. May was chosen for its historical significance to Asians in America: The first Japanese immigrants arrived to the U.S. on May 7, 1843, and May 10, 1869 marked the completion of the Transcontinental Railroad. This is significant because the Central Pacific Portion of the railroad (West to East portion) was constructed by Chinese laborers. The week expanded to a month in May 1990 and became permanently known as Asian/Pacific American Heritage Month in May 1992.

pg.4-5,8|Additive Manufacturing Capabilities Bring Concepts to Life with 3-Dimensional Imaging pg.6|German Engineer Expands Network, Culture through Temporary Placement in the United States pg.7|This May we celebrate the 14th annual National Military Appreciation month

Ask a Tech Tip: Changing Oil Mike Kauzlarich, of the Pyrotechnics and Explosives Branch, reveals how the techniques and lessons learned in labs can help you solve your household problems. Submit a question to him at usarmy.APG.ecbc.mbx.engineering-directorate@mail.mil.

In recent weeks, The Engineering Edge has received questions concerning engine oil. Two of the most pertinent questions concern how often you should change the oil and if there are any oil additives you can add to the oil to help your engine run better and last longer.

At a minimum you should follow the car manufacturer’s recommendation, however in severe service, changing oil every 3000 miles would be better. But pay attention to the manufacturer’s definition of severe service. If you make many short trips or do stop and go driving (city) that is severe service. Change the oil more often.

As far as additives go we think you should only be concerned if you drive an older/ non-catalytic converter car. Prior to the days of catalytic converters most engines were flat tappet camshaft engines and needed a chemical called ZDDP (dialkyldithiophosphate) to help lube the wear parts of the engine. It was removed from oil after catalytic converters showed up on cars as the engine designs changed to roller camshafts and ZDDP shortened the life of catalytic converters.

This newsletter was published through the Balanced Scorecard.

For article suggestions, questions or comments please contact Ed Bowen at edward.c.bowen8.civ@mail.mil

So only worry about additives with ZDDP if you’re driving a very old pre-mid 1980’s car without a catalytic converter.

SharePoint Tip: SET UP ALERTS SharePoint can be configured to send you an email or an SMS text message whenever things are changed on either a specific item in a library or if anything in a library as a whole changes. This is useful since you won’t then have to go back and manually check each SharePoint site for changes. You can set up alerts using the Alert Me button in the Ribbon on any given SharePoint content area.

Clicking it brings up the New Alert window, where you add a title to the alert, the delivery method (as mentioned, either an email to a specified address or a phone number for an SMS text message), the context of the alert (whether an alert is sent for any change at all, or only if new items are added, if existing items are modified, or if items are deleted), the scope of an alert (if anything changes, if a document changes, if a document you created or last modified changes), and how quickly the alert is sent after a change (you can set up an immediate alert, a daily summary, or a weekly summary, and you can customize the time for this).

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The Engineering Edge | May 2013| 3

ECBC Engineers Overcome Time Restraints and Challenges to Field LVOSS Abroad

I

n an Army motor pool in Germany, half a dozen people are wielding wrenches, drills, and components. The noise of the drill dominates, as soldiers concurrently drill mounting holes into Humvees. Inside of those same Humvees, others are installing wiring harnesses and connecting batteries. Tasks (and tools) are handed off as soldiers file out and back in, called to attend to other duties and subsequently return from them. A general mechanic’s toolkit rests in the middle of the workspace. The group is made up of soldiers of various ranks and two civilians – a program manager from ECBC and a Total Package Fielding (TPF) Representative from TACOM. To the untrained eye, the scene looks like chaos.

“I think the Special Troops Battalion of the 173rd Airborne Brigade were surprised when we put our hands on the LVOSS and actually helped them install.

Apparently most people stop at showing them what to do. I would just hop onto the vehicle to get things started.”

– Rich Dixon, ECBC’s LVOSS M327 Program Manager

“It’s under control,” said Richard Dixon, ECBC’s Light Vehicle Obscuration Smoke System (LVOSS) M327 Program Manager, and General Engineer with the Smoke Systems/Riot Control Team in Rock Island, Il. “It can look like chaos, but I’m managing everything.”

The LVOSS is a defensive system designed specifically for Military Police (MP) during crowd management. When a military vehicle has an LVOSS installed, it provides four dischargers which can be loaded with different grenades as the situation dictates. One grenade is a smoke round, providing a screen that allows an MP unit to break contact with an enemy and egress from a situation. Another can dispense a riot control agent, such as tear gas. The LVOSS can also launch flash bang grenades that distract an enemy or launch a blunt trauma grenade which spreads rubber balls over the area. The LVOSS can be used by MPs anywhere for riot control, including current Theaters.

The first vehicle was equipped with LVOSS in 1999 – however the latest iteration, the M327, was initiated in 2007.

“The M327 is mounted on the M1151 armored Humvee, which replaces the M1114 Humvee,” said Dixon. “LVOSS was designed to be installed on the M1114 Humvee, but because of the current Improvised Explosives Device situation, additional armor had to be added to the M1114, to the point that it was no longer feasible. So the next generation Humvee, the M1151, was developed with more armor. Once the M1151 showed up, we didn’t have an LVOSS installation kit; we had to develop the kit.”

Recently, the M327 teams accomplished a new milestone– fielding eight LVOSS kits to the 173rd Airborne Brigade Combat Team in Germany in just two days.

“Typically, three days is a comfortable amount of time, especially when working outside of the country,” said Dixon.

Rich Dixon helped field eight Light Vehicle Obscuration Smoke Systems to the 173rd Airborne Brigade Combat Team in Germany.

However, when Dixon and TPF Representative Michelle Boerner arrived onsite at Warner Barracks in Bamberg, Germany, they faced their first challenge.

“The Motor Pool Sergeant had other needs for the space,” said Dixon, referring to the motor pool. “So we had two days.”

The first day, Boerner planned to work with supply representatives to issue the LVOSS kits to soldiers. That is when the second challenge arose. “The supply reps weren’t available; soldiers have a lot of other responsibilities,” said Dixon. Eventually, the team was able to secure permission to obtain one LVOSS kit and get started. Later that afternoon, the supply representatives were available to sign out the remaining seven LVOSS kits.

And thus installation commenced, with Dixon taking command of the process by demonstrating just how that process should go. The kits are designed to be easy to install, without a need for specialized tools – only those provided in the Army issue general mechanics toolkit. The installations went smoothly.

“The person in charge needs to know what they’re doing and be able to organize the installation in a logical manner, so that installation can progress as quickly as possible,” Dixon explains. “A team of four to five soldiers can be working concurrently on a series of specialized tasks: hooking up a battery, drilling mounting holes, and connecting wiring harnesses – all of those tasks can be done simultaneously, you may just need to wait for someone to finish their assigned task. Organization is key to getting this done in an expeditious manner.”

During the installation process, soldiers are frequently called away to attend to their other responsibilities – and both Dixon and Boerner are able to jump in, seamlessly taking over where the task left off.

Dixon said, Borener, a retired Non-Comissioned Officer, was able to go outside of her normal TPF Rep duties and dive right in. “I think the Special Troops Battalion of the 173rd Airborne Brigade were surprised when we put our hands on the LVOSS and actually helped them install. Apparently other contractors stop at showing them what to do. I would just hop onto the vehicle to get things started.”

In the end, the team was able to overcome challenges and time restrictions to successfully field the eight LVOSS kits.

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Additive Manufacturing Concepts to Life with “Sure, the technology is available for home use, but we feel the higher functionality and capability we have been able to achieve has been a credit to the team I have put together, combined with our accessibility to unique projects provided by ECBC and other Department of Defense organizations.”

– Rick Moore, Rapid Technologies and Inspection Branch Chief

Photos Courtesy of U.S. Army RDECOM

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The Engineering Edge | May 2013| 5

Capabilities Bring 3-Dimensional Imaging W hat can $2k buy you today? For hobbyists, artists and even small design firms it can buy them a low cost, entry level, ready-to-run desktop 3D-printer, such as the Replicator™2 from MakerBot® or the Cubify® from 3D Systems™.

In recent news, this technology has gained notoriety due to its ability to reproduce everything from critical gun parts with full functionality, to exact replicas of children’s toys. 3D printing has even made an appearance in recent pop music videos, transporting viewers through a seemingly futuristic odyssey to clone a high-tech version of will.i.am. However, Branch Chief Rick Moore of the Rapid Technologies and Inspection Branch at the Edgewood Chemical and Biological Center’s (ECBC) Advanced Design and Manufacturing Division notes however, “more than toys or gun parts can be produced with these Additive Manufacturing technologies.”

Additive Manufacturing (also known as rapid prototyping or 3D printing) is the process of making a three-dimensional solid object of virtually any shape from a digital model. Having this capability has increased the speed at which products are brought to market, while also proving to be ideal for testing, which allows for cost-effective design changes during the preproduction cycle of a product.

Moore and his team have been utilizing these revolutionary processes and capabilities to produce items in support of the Warfighter and the Homeland, all within their Rapid Technologies lab on-campus at ECBC. “3D-printing and 3D laser scanning are capabilities we’ve had here since the mid-1990s,” said Moore. “These capabilities help us get equipment in the hands of the Warfighter quicker, and it also provides access for other engineering and science groups to design products with the ability for many iterations or design changes before fully investing critical funds into the mass-production of that item.”

In the simplest of concepts, as Moore explains it, “…it’s a process that can take an idea that has been drawn on a napkin and transform it into a 3D product that you can look at, feel and test in a matter of hours or a few short days.”

“Additive Manufacturing technologies allow people to design something quickly and then produce an affordable physical model that can be thoroughly inspected, discussed and tested before additional money is invested or items are fielded,” adds Lester Hitch, an engineering technician in the Rapid Technologies and Inspection Branch.

The Look and Feel of Engineering

Additive Manufacturing has paved the way for several new technologies that will change the landscape of the Army, such as the Octopus-inspired suction cups developed by US Army Research Laboratory (ARL) scientists with the assistance of Moore’s Rapid Technologies and Inspection Branch. These self-sealing suction cups, conceptualized by Chad Kessens of ARL during his post-graduate research in robotic manipulation, were produced with the assistance of engineering technician Brad Ruprecht from the Rapid Technologies and Inspection Branch, using the Objet Connex500 multi-material 3D-printer.

These robotic suction cups are able to maximize suction force and the passive reaction forces that cause the cup to activate and open when the lip contacts an object, breaking the seal to initiate suction.

“Using the multiple digital material options afforded by the Connex500 allowed us to blend variations of elastomeric and rigid materials at the same time, into the same product. That otherwise would be very difficult if not nearly impossible to manufacture traditionally,” Ruprecht said.

The Rapid Technologies Branch also supported prototyping of the Anthropomorphic Control Arm (ACA), a recent project of the Advanced Design and Manufacturing Division’s in support of the Defense Threat Reduction Agency Robotics.

“The ACA is an intuitive joystick developed to control a hydraulic actuating arm and claw mounted on a military vehicle. Much like how a human arm has wrist, elbows and the ability to twist or extend, the ACA has joints that mimic these motions to manipulate the vehicle mounted arms in a fashion that requires little to no training between operators,“ Ruprecht said.

The ACA project has been through multiple design iterations ranging from simple wood or cardboard models that test ergonomics to more involved designs built using polycarbonate or nylon plastic materials that support the integration of electronics and sensors that allow full functionality testing.

Beyond the Additive Manufacturing capabilities of the branch, there is also a highly capable 3D scanning department supported by engineering technician Ryan Gilley.

“3D scanning is great for recreating organic items, such as those fitted to human anatomy – or even exploded fragments – and for items involving prismatic geometry, like hole-patterns or custom brackets,” said Gilley.

Continues to Page 8

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German Engineer Expands Network, Culture through Temporary Placement in the United States

S

ven Fiebing has some advice for anyone considering a foreign work exchange program, “Do it.

Don’t think too long – it’s a very impressive program, and it only has a positive effect.”

Fiebing, an Engineer from Germany, is halfway through a one-year, one-time foreign exchange program supporting Edgewood Chemical Biological Center’s Advanced Design and Manufacturing Division. Along with his wife and two children, Fiebing temporarily relocated to the U.S. to take on a new challenge and expand his international network.

The program, called the Engineer and Scientist Exchange Program (ESEP), commemorates its 50th year of partnership between the U.S. and Germany this year. A reception, hosted by the two countries, was held in April at Joint Base Anacostia-Bolling in Washington, D.C. Event invitees include German and U.S. ESEP participants, supporters within the program, ECBC’s Technical Director, Joseph Wienand, and the Army, Navy and Air Force.

Since 1996, five German engineers and scientists have been placed within ECBC through participation in the program.

Historically, the U.S. has taken on more participants than it has dispersed by a large margin, due to the strain of funding on participating commands prior to 2006. Since then, a fund has been established by the Office of the Deputy Assistant Secretary of the Army for Defense Exports and Cooperation (DASA [DE&C]) to provide reimbursement to commands to assuage any financial concerns.

However, current constraints have put a hold on scientists and engineers looking to participate in the program abroad.

“I know of two people within ECBC whose deployment to the program has been placed on hold as a result of the current circumstances,” said Emma Forrest, International Program Management Specialist with ECBC. Currently, there are ECBC personnel stationed in Chile and Australia through the ESEP. The ESEP includes partnerships between the U.S. and 17 other countries, including the United Kingdom, Japan, Israel, and the Netherlands. For nonEnglish speaking country exchange, applicants must undergo a language proficiency screening.

“The hardest part of working here is the language,” said Fiebing. “That, and the measurement system.” As an engineer, Fiebing works in measurements daily; while the units of measure may be different, the workday, he has found, is not.

“The routine here is very much the same as being a civil servant or government worker in Germany,” says Fiebing. “No big differences.” At home in Germany, Fiebing supports the Bundeswehr Research Institute for Protective Technologies and Nuclear, Biological and Chemical Detection, where he

has worked in the contamination field for over a decade. Since 2010, Fiebing has supported a program to ensure water purification and potability for soldiers. For ECBC employees and support personnel, that work may sound familiar.

“It’s interesting to see the same issues being addressed in Germany as those faced by ECBC, like decontamination of materials, for instance,” said Lester Strauch, Engineering Design & Integration Branch Chief within ADM. “The German government really parallels the U.S. government in that way.”

In fact, Fiebing’s coworkers back at his home base at Bundeswehr work closely and often with ECBC engineers, operating as sister organizations. There are currently seven Data Exchange Annexes in place between the two organizations for chemical biological, smoke, and environmental information, according to Forrest.

“Now ECBC is no longer just another institute I’ve heard of. I’ve gained a different perspective, being here. I have new colleagues, and am in a position to call on my contacts even after I return to Germany.”

– Sven Fiebing, German engineer working with ECBC through ESEP Program

Since August, Fiebing has worked on various projects, such as the Husky Mounted Detection Surrogate System (HMDSS).

Previously, there was an issue with the front panels being pivotal joints; Fiebing helped redesign and rebuild the front panels for a better and more cost effective model. Fiebing has also assisted with optimizing a clip for the Minehound Mine Detection System. After noticing potential weaknesses with the design, Fiebing helped generate a 3D rendering of the clip drawing and conducted simulated stress tests to determine how the design could be improved. He has also sat in on multiple design reviews to assist with optimization using his technical knowledge of materials.

“I don’t have a lot of restrictions, so I can move freely between projects and teams – there are always opportunities to meet with other teams to discuss their programs,” said Fiebing.

This freedom has allowed Fiebing to maximize the number of contacts he has gained during his exchange program, which can help him on the job once he returns to Bundeswehr.

“Now ECBC is no longer just another institute I’ve heard of.

I’ve gained a different perspective, being here. I have new colleagues, and am in a position to call on my contacts even after I return to Germany,” said Fiebing.

Fiebing said the main reason to participate in the exchange program is to learn more about the culture – the way the engineers at ECBC work and live.

“It’s a career broadening experience,” said Forrest. “It’s about building relationships – ECBC has very strong relationships with our counterparts in Germany.”

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The Engineering Edge | May 2013| 7

This May we celebrate the 14th Annual National Military Appreciation month Legislature to designate the observance, Military Appreciation Month, was first passed by the Senate in 1999 to notify service members that their country has set aside an entire month to honor, remember and appreciate them. In 2004, more comprehensive legislation was passed by both houses of Congress, urging the President to issue an annual proclamation calling on the American people to recognize the country’s service members through ceremonies and events.

May was chosen because it has the most already days set aside for military commemoration. These holidays include: • May: Military Appreciation Month; Military History Month • 1 May: Loyalty Day

From the Congressional Resolution urging the President to issue an annual proclamation of observance: Whereas the vigilance of the members of the Armed Forces has been instrumental to the preservation of the freedom, security, and prosperity enjoyed by the people of the United States; Whereas the success of the Armed Forces depends on the dedicated service of its members, their families, and the civilian employees of the Department of Defense and the Coast Guard; Whereas the role of the United States as a world leader requires a military force that is well-trained, well-equipped, and appropriately sized;

• 8 May: V-E Day • 10 May: Military Spouse Appreciation Day • 13-18 May: Military Appreciation Week • 18 May: Armed Forces Day • 27 May: Memorial Day Events and observances are held annually at Aberdeen Proving Ground, including luncheons, guest speakers’ series, and ceremonies. For the latest information, visit: apg.army.mil

Whereas the Federal Government has a responsibility to raise awareness of and respect for this aspect of the heritage of the United States and to encourage the people of the United States to dedicate themselves to the values and principles for which Americans have served and sacrificed throughout the history of the Nation…

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Test your military knowledge 1. Name the five branches of the Armed Forces.

2. Who is the Chairman of the Joint Chiefs of Staff?

3. What percent of 17-24 year olds does the military estimate to meet its required moral, academic, and physical standards?

4. What is the oldest branch of the Armed Forces?

5. Whose picture is on the Purple Heart medal?

6. How many of the 44 Presidents have been veterans?

Answers can be found on page 8

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Additive Manufacturing Capabilities Bring Concepts to Life with 3-Dimensional Imaging Continued From Page 5

well. While the general public is concerned about those who would use the technology to bypass laws for gun production with a $2k printer, Moore and his engineers hope that a few users won’t mar the technology and the possibilities for everyone else.

It’s a process that can take an idea that has been drawn on a napkin and transform it into a 3D product that you can look at, feel and test in a matter of hours or a few short days.”

– Rick Moore, Rapid Technologies and Inspection Branch Chief

The Rapid Technologies and Inspection Branch’s combination of state-of the-art Additive Manufacturing equipment and passionate experts shape the future of Army engineering.

“Sure, the technology is available for home use, but we feel the higher functionality and capability we have been able to achieve has been a credit to the team I have put together, Photo Courtesy of U.S. Army RDECOM combined with our accessibility to unique projects provided by In cases of evidence collection, exploded fragments provided ECBC and other Department of Defense organizations,” said

by ARL’s Survivability/Lethality Analysis Directorate (ARL-SLAD) Moore. can be scanned and accurately recreated for various uses, The Rapid Technologies engineers truly care about utilizing such as lightweight replicates that preserve the integrity or this capability to make the world a better place for the security of the physical sample. In fact, components from Warfighter: “We want to be a part of the driving technology an entire vehicle system can be scanned and recreated in a behind the evolution of additive manufacturing in the 3D-CAD environment to very accurate detail to assist groups Army and can hopefully shape its future into something like the Letterkenny Army Depot in the production of Minemeaningful,” Hitch reflects.

Resistant Ambush Protected vehicles.

They are halfway there. Hitch said some manufacturers have Additive Manufacturing for the Common Man already come to them for their opinion on the technologies While the engineers of the Rapid Technologies and Inspection and materials.

Branch are using their 3D equipment to make life safer for the “We like contributing and we want to use our tools to help the Warfighter, they recognize its presence in popular culture as Army improve and evolve,” Moore said.

Did you just complete a project milestone? Is there someone fascinating in your Division? Maybe you’re just tired of reading about other teams, and want people to learn about your s. Then send ar ticle suggestions to Ed Bowen at edward.c.bowen8.civ@mail.mil. Ar ticles from The Engineering Edge are used to tell internal and external audiences about the excellent capabilities and exper tise available in our Directorate. Are you ready to share your project with the world?

(Answers: 1: Army, Navy, Marine Corps, Air Force, Coast Guard; 2: General Martin Dempsey; 3: 25%; 4: Army; 5: President Washington; 6: 31) APPROVED FOR PUBLIC RELEASE