SBIR-STTR Award

SBIR Phase I DLA192-001 represents a requirement for Reverse Engineering (RE) of an obsolete Circuit Card Assembly (CCA). In this SBIR Phase I effort, Global Circuit Innovations (GCI) will collect and organize all available specifications and drawings for NSN: 5998-01-255-1802. GCI will visit the organization responsible for supporting this requirement to acquire as much information as possible. GCI will request to see the physical CCA and, if possible, take one sample CCA for further analysis and evaluation. GCI will locate a source (through procurement or identify a GCI redesign effort if required) for all of the components on the CCA and will create a schematic, if one is not already available, for this CCA. A schematic can be created even in the absence of a Technical Data Package (TDP) from an analysis of the CCA. GCI will also create a Source Approval Package (SAR). This information would later be used in a follow-on SBIR Phase II to layout, manufacture, populate and fully test a form, fit and function, backwards-compatible CCA that works perfectly in the customer’s system.

Reverse Engineering of Circuit Card Assembly (CCA) – The Phase I SBIR effort determined that there was a need for Failure Analysis effort to address replacement for a Circuit Card Assembly (CCA). This CCA is not obsolete and there is DLA stock. However, the end user has indicated they have had high failure rates for the past 10 years and are seeking a new source of supply. GCI has implemented failure analysis on this part to determine the issue and therefore, will determine a path forward to reverse engineer this CCA to provide a form, fit and function CCA that will be reliable and meet all specification in the Phase II effort. It will also be tested and work successfully in the customer’s next higher assemblies: SRU and LRU. The corresponding NSN for this CCA is 5998-01-549-7929. The ESA (Engineering Support Authority) for this project is Mr. Scott Mahoney, Product Realization Engineer Supporting Lower Tier Project Office (PATRIOT) & CECOM ILSC Power & Environmental Directorate, C5ISR Center, Product Realization Systems Engineering & Quality Directorate (PRD) U. S. Army Combat Capabilities Development Command (CCDC). Obsolete Resistor Assembly – In the Phase I SBIR effort, it was determined that there was a need for a replacement for an obsolete Resistor Assembly used on the B-52 aircraft, NSN 5905-00642-1235. The Engineering Support Authority (ESA) for this project is Blaine Finley, AFLCMC/WWDEA, B-52 Avionics Engineer. GCI worked with Thom Farleigh of Bill McClung, Inc. to purchase a Technical Data Package and a sample resistor part. GCI has spent considerable time reviewing the final technical drawings and the Bill of Materials (BOM), testing requirements, and sources of supply for all components. In the Phase II program, GCI will continue the engineering approach inititiated in Phase I to test and qualify a form, fit and function drop-in replacement resistor assembly that meets all requirements and works successfully in the customer’s next higher assemblies: Shop Replaceable Unit (SRU) and Line Replaceable Unit (LRU). Obsolete Hermetically Packaged Microprocessor – The Phase I SBIR effort also determined that there was a need for a replacement for a microprocessor, commonly used throughout the DoD, NSN 5962-01-334-8159. The ESA for this project is Tuan M. Ha, 422 SCMS/GUEAB, Tinker AFB, OK. In the Phase II program, GCI will continue the engineering approach initiated in Phase I to test and qualify a form, fit and function drop-in replacement resistor assembly that meets all requirements and works successfully in the customer’s next higher assemblies: SRU and LRU.