office of the under secretary of defense

3000defensepentagon

washington, dc 20301-3000 

ACQUISITION,

TECHNOLOGY

AND LOGISTICS

 Our Soldiers, Airman, Sailors, and Marines continue to fight on multiple fronts and in 

diverse environments where they are supported by the most capable, dynamic, and competent 

industrial base in the world. It is one of our critical responsibilities as the Department of Defense 

to monitor, engage, and invest in our national industrial base to ensure those Warfighters have 

the systems necessary to successfully execute their daily missions. My office, Manufacturing 

and Industrial Base Policy (MIBP), carries out this mission on behalf of the Under Secretary of 

Defense for Acquisition, Technology, and Logistics. A central element of these efforts is the 

Manufacturing Technology (Man Tech) program. For over 50 years, The DoD ManTech program 

has been the Department’s investment mechanism for staying at the forefront of defenseessential manufacturing capability. ManTech focuses on the timely development, production,

and sustainment of defense systems, and thereby enhances our affordability and technological 

edge in a dynamic, diverse, and evolving threat environment. 

 This annual brochure highlights the Warfighter impacts of products and processes 

transitioned to use by the ManTech programs of the Office of the Secretary of Defense, the 

Departments of the Army, Navy, and Air Force, and the Defense Logistics Agency. The success 

stories enclosed demonstrate the ability of ManTech programs to provide affordability, reduce 

manufacturing lead time, provide faster surge capabilities, improve technology implementation, 

improve manufacturing processes for greater reliability, and rapidly respond to Warfighter 

requirements. 

 This year’s center section highlights the changes brought on by the 2011 National 

Defense Authorization Act to ensure responsiveness to the Department’s current and future 

industrial base needs. Changes include the formation of my new position as Deputy Assistant 

Secretary of Defense for MIBP, and aligning oversight of the ManTech Program and its 

associated Joint Defense Manufacturing Technology Panel (JDMTP) under MIBP.

 One of the key thrusts of the MIBP office’s mission is to partner with industry to inject a 

new spirit of innovation into the Department to ensure our Warfighters are the beneficiaries of 

the best technology advances that industry can provide. 

 I see ManTech as a key to fostering that innovation by meeting the challenge of our 

changing world and ensuring our Nation maintains its competitive edge on the battlefield. I am 

pleased to lead and be a part of the ManTech team, which continues to enhance our national 

security industrial base for the protection of our future.

 Sincerely,

 Brett B. Lambert

 Deputy Assistant Secretary

 Manufacturing and Industrial Base Policy

ncerely,

BL b
MISSION STATEMENT

The DoD Manufacturing Technology (ManTech) Program anticipates and closes gaps in 

manufacturing capabilities for affordable, timely, and low-risk development, production

and sustainment of defense systems.

FOCUS

An important focus of ManTech is on the manufacturing technologies, processes, and enabling 

production capabilities that reduce the acquisition and sustainment cost of weapon systems, and 

provide direct benefit to the Warfighter. Measures of effectiveness include improved mission capability, 

improved readiness, and reduced total ownership costs. Timely transition of the technology consistent 

with acquisition and operational requirements is essential. 

STRATEGY

The DoD Manufacturing Technology Program Strategic Plan prepared in 2009 by the Office of the 

Secretary of Defense in close collaboration with the JDMTP contains four strategic thrusts: 

  r5ISVTU&GGFDUJWFNBOBHFNFOUBOEEFMJWFSZPGQSPDFTTJOHBOEGBCSJDBUJPOUFDIOPMPHZ  

solutions

  r5ISVTU"DUJWFTVQQPSUGPSBIJHIMZDPOOFDUFEBOEDPMMBCPSBUJWFEFGFOTFNBOVGBDUVSJOH  

enterprise

  r5ISVTU"DUJWFTVQQPSUGPSBTUSPOHJOTUJUVUJPOBMGPDVTPONBOVGBDUVSBCJMJUZBOENBOVGBDUVSJOH 

process maturity

  r5ISVTU"DUJWFTVQQPSUGPSBIFBMUIZ
TVGGJDJFOUBOEFGGFDUJWFEFGFOTFNBOVGBDUVSJOH  

infrastructure and workforce

The ManTech Program strategy is to balance its traditional emphasis on processing and fabrication 

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defense manufacturing relies on a networked, collaborative, and increasingly global supply base, with 

capabilities that can be linked between and among all stakeholders – from developer to user to sustainer 

– to respond rapidly to dynamically changing defense needs. 

 The ManTech successes documented herein are categorized by the appropriate strategic thrust. The 

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Deputy Assistant Secretary of Defense of Manufacturing and Industrial Base Policy (MIBP) and moves 

the DoD ManTech office under the oversight of the Office of MIBP.

VISION

 “A responsive world-class manufacturing capability to affordably and rapidly 

meet Warfighter needs throughout the defense system life cycle.”
ARMY

THRUST ONE

PROCESSING & FABRICATION

The Challenge:

The Warfighter needs a safer, more reliable and affordable ignition system to replace its primer-based ignition 

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however standard processes to manufacture laser ignition are immature and unable to meet large caliber artillery 

weapons size, weight, cost, and performance requirements.

ManTech Response:

r Army ManTech developed and demonstrated robust and affordable manufacturing processes for 

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r Formulated unique manufacturing methods that conform to thermal, high shock, configuration, 

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Impact:

r Demonstrates a safe, reliable propellant ignition system for the Warfighter and enables remote, 

 automated fire

r Advances diode laser technology by increasing diode temperature operation capability beyond 

 current industry’s capability (from 85o C to 115o C)

r *ODSFBTFTMBTFSJHOJUJPOTZTUFNNBOVGBDUVSJOHSBUFGSPNUPMBTFSJHOJUFSVOJUTQFSEBZ

Reduces diode laser igniter unit production cost by ~50% (from $55K to $27K )

U.S. Army RDECOM Armaments Research, Development and Engineering Center,

Technology Transition Initiative (TTI), Lasertel, LDAI

ManTech Develops Laser Ignition Manufacturing Processes 

for Large Caliber Artillery Weapons Application

Page 1

LW155 M777A2 Lightweight Howitzer

LW155 DPLIS Spindle Assembly

Laser Igniter

LW155 Spindle Assembly

Vent
Page 2 NAVY

The Challenge:

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DPNQPTJUFTUPSFEVDFXFJHIUBOE

improve operational performance. Optimization of the automated fiber placement (AFP) process for BMI material 

is necessary to enhance productivity and make the fabrication of wing skins and nacelle structure more affordable. 

ManTech Response:

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)JUDP$BSCPO$PNQPTJUFT
."( 

 $JODJOOBUJ
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 in the manufacturing environment

r Designed experiments were used to identify material and machine interactions and the effects of 

 process parameters 

r Process modifications, including installation of infrared heating technology and use of high density 

 polyethylene components to reduce friction, were tested and validated

r /BWZ.BO5FDIJOWFTUNFOUPG.

Impact:

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 structure 

r Manufacturing protocols and support fabrication technology inserted real-time into the production of 

 áJHIUIBSEXBSFGPSBMMUISFFWFSTJPOTPGUIF+4'BJSDSBGU$7
4507-
BOE$50-

r 1SPEVDUJPOUSBOTJUJPOPGUIFTF.BO5FDIQSPUPDPMTBDDPNQMJTIFEXJUIUIF+4'8JOHBOE/BDFMMFTLJO 

 AFP partners

r Fabrication schedules compressed and capital equipment investment reduced

ManTech Increases Affordability of 

Joint Strike Fighter by Improving Fiber Placement

Estimated cost savings of $100M

Navy ManTech, Composites Manufacturing Technology Center, Lockheed Martin Aerospace, 

Hitco Carbon Composites, MAG Cincinnati, Cytec Engineered Materials, JSF Program Office

THRUST ONE

PROCESSING & FABRICATION

Optimized 

automated fiber 

placement of 

BMI carbon fiber 

tape improves 

JSF affordability
AIR FORCE

The Challenge:

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NJTTJPO

flexibility, survivability, and standoff range. 

ManTech Response:

r "JS'PSDF.BO5FDIXPSLFEXJUI)POFZXFMM"FSPTQBDFUPJNQSPWFUIFNBOVGBDUVSJOHQSPDFTTGPSCPUI

 *OUFHSBUFE.JDSP&MFDUSP.FDIBOJDBM4ZTUFN	.&.4
"DDFMFSPNFUFSBOE(ZSPTFOTPST

r Increased manufacturing throughput by developing the ability to screen sensors at the chip level 

 before assembly

r .BUVSFEUFDIOPMPHZUPB.BOVGBDUVSJOH3FBEJOFTT-FWFM	.3-
PGGPSUIF*OUFHSBUFE.&.4 

 "DDFMFSPNFUFSBOE.3-GPSUIF(ZSP

r "JS'PSDF.BO5FDIJOWFTUFEPWFS.XIJMFDPMMBCPSBUJOHXJUI"SNZBOE/BWZ.BO5FDI

Impact:

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r 3FEVDFEDPTUPG*OFSUJBM.FBTVSFNFOU6OJUT	*.6T
GSPN,VOJUUPMFTTUIBO,VOJU

r Increased aided and unaided navigation accuracy, increased g-hardness, and reduced susceptibility 

 to external jamming

r "DDFMFSBUFE-PX3BUF*OJUJBM1SPEVDUJPOCZZFBSTGPS)POFZXFMM*.6T

Cost avoidance of over $200M for 111,000 munitions

Air Force ManTech, Honeywell Aerospace, Army ManTech, Navy ManTech

ManTech Increases Manufacturing Throughput 

of Integrated MEMS Packaging

Page 3

THRUST ONE

PROCESSING & FABRICATION

HG 1940 

MEMS
Page 4

The Challenge:

.FBMT3FBEZUP&BU	.3&
FOUSFFTBSFDPOUBJOFEJOIFSNFUJDBMMZTFBMFENVMUJMBNJOBUFGPJMQPVDIFT5IFàMMJOH

process occasionally leaves entrapped matter in the seal area which prevents the pouch from being reliably 

sealed with traditional heat sealing methods.

ManTech Response:

r %-"T$PNCBU3BUJPOT/FUXPSLGPS5FDIOPMPHZ*NQMFNFOUBUJPO	$03"/&5
QSPHSBNEFNPOTUSBUFE 

 QSPPGPGDPODFQUGPS.3&VMUSBTPOJDTFBMQSPEVDUJPONFUIPEUPSFMJBCMZTFBM.3&QPVDIFT

r Ultrasonic seals meet or exceed package-integrity requirements even with significant seal-area 

 contamination

r %-".BO5FDIJOWFTUNFOUPG.

Impact:

r Improved food safety with fewer defects

r EFDSFBTFJOQSPEVDUSFXPSLDPTUT

r Production lines fully implemented at all ration producer facilities to include AmeriQual, 

 8PSOJDL'PPET
BOE401",$0

ManTech Improves Quality and Assures Safety of

Meals Ready-to-Eat for Our Military 

DEFENSE LOGISTICS AGENCY

Cost savings of $1.5M/year in quality assurance and rework

DLA, Army, Navy, Marine Corps, USDA, Food Industry, Universities

THRUST ONE

PROCESSING & FABRICATION

Ultrasonic MRE Sealer Unit
NAVY Page 5

The Challenge:

/VNFSPVT àUUJOHTNVTU CFNBOVBMMZ áBNF CSB[FE VTJOH B IBOEIFMEUPSDI EVSJOH $7/ $MBTT BJSDSBGU DBSSJFS

BOE7*3(*/*"$MBTTTVCNBSJOF	7$4
DPOTUSVDUJPOBOESFQBJS5IFQSPDFTTJTMBCPSJOUFOTJWFBOEDBOSFTVMUJO

occasional paint damage and pipe leaks. The rework required is time-consuming and costly.

ManTech Response:

r Developed a portable flame brazing system using a programmable logic controller, mass flow 

 controllers, and a burner that surrounds the fitting 

r (FOFSBUJOHUIFCSB[JOHQSPDFEVSFTGPSTIJQZBSEJNQMFNFOUBUJPO

r /BWZ.BO5FDIJOWFTUNFOUPG.

Impact:

r Reduced the time required to braze each joint

r Decreased the need for rework

r Reduced pipe fitter training time

r Result is production cost savings

r %JSFDUJNQBDUPO$7/7$4XJUIBQQMJDBCJMJUZUPPUIFSTIJQQMBUGPSNT

ManTech Reduces Shipbuilding Costs

with Alternative Flame Brazing Technology 

Estimated cost savings of $2.3M

Navy ManTech, Navy Metalworking Center, CVN Program Office, VCS Program Office, 

Naval Surface Warfare Center Carderock Division, Newport News Shipbuilding, Lean Engineering

THRUST ONE

PROCESSING & FABRICATION

Shipbuilding costs are reduced by brazing pipe joints shipboard with a small, 

lightweight heating system as opposed to the current method of torch brazing.
Page 6 AIR FORCE

The Challenge:

#PUIUIF'BOE'SFRVJSFBQQSPYJNBUFMZ
GFFUPGWBSJPVTTIBQFETFBMTQFSBJSDSBGU
UIBUBSFJOTUBMMFE

BSPVOEGSFRVFOUMZBDDFTTFENBJOUFOBODFQBOFMT'PSUIF'
UIFDVSSFOUQSPDFTTDZDMFJODMVEFTBTJHOJàDBOU

amount of touch labor required to assemble the mold, inject, disassemble and de-mold the part.

ManTech Response:

r "JS'PSDF.BO5FDIBOE"'3-391XPSLFEXJUIUXPDPOUSBDUPSTUPEFWFMPQBUIFSNPQMBTUJDFYUSVTJPO

 QSPDFTTUPJNQMFNFOUFYUSVEFETFBMTXJUIUIFTBNFàMMFSNBUFSJBMVTFEJO'DBTUTFBMT

r Air Force ManTech helped the F-22 program improve their extruded material formulation based on the 

 'TFYUSVEFETFBMT

r %FWFMPQFEBOEWBMJEBUFEBKPJOURVBMJàDBUJPONBUSJYGPSCPUI'BOE'QSPHSBNTXIJMFCPUI 

 programs worked to qualify the material for implementation

r "JS'PSDF.BO5FDIJOWFTUFE.

Impact:

r *ODSFBTFEUIF'QSPEVDUJPOSBUFBOESFEVDFEDPTUCZFMJNJOBUJPOPGUPVDIMBCPS

r 3FEVDFE'QSPEVDUJPOUPPMJOHCZ

r *ODSFBTFT'TFBMQSPEVDUJPOSBUFPOBOPSEFSPGPOFGPPUQFSNJOVUFDPNQBSFEUPUIFDBTUQSPDFTT

 of one foot per hour

r /FXFYUSVEFENBUFSJBMGPS'XJMMIBWFTVQFSJPSEVSBCJMJUZDPNQBSFEUPCBTFMJOFNBUFSJBM
SFTVMUJOH 

 in lower maintenance costs

r 5BTLTBEEFEUPQSPHSBNGPSUIFQSPEVDUJPOPG'UBQFXJMMSFTVMUJOGVUVSFQSPEVDUJPODPTUBWPJEBODF

 PGBOBEEJUJPOBM.

Expected total cost avoidance of $881M for extruded seals

Air Force ManTech, AFRL/RXP, ARC Technologies, Cuming Microwave Corp, 

Lockheed Martin, Universal Technology Corp 

ManTech Reduces Costs and Increases Reliability 

of Extruded Seals for F-35 and F-22

THRUST ONE

PROCESSING & FABRICATION
DEFENSE-WIDE MANUFACTURING SCIENCE AND TECHNOLOGY (DMS&T)

Page 7

The Challenge:

In the current engagement, more Warriors are surviving injuries and living with amputations. Our military care 

system is strained by the increased numbers of amputations, and by the functional demands to which our young 

8BSSJPSTXBOUUPCFSFTUPSFE/FXPQQPSUVOJUJFTBSFBWBJMBCMFUPJNQSPWFUIFQSPDFTTJOHBOENBOVGBDUVSJOHPG

prosthetic systems to increase durability and comfort and to provide medical personnel the tools to care for our 

most deserving heroes.

ManTech Response:

r %.45QBSUOFSFEXJUIUIF0GGJDFPG/BWBM3FTFBSDI	0/3
UPESBNBUJDBMMZJNQSPWFUIFRVBMJUZBOE 

 comfort of sockets for lower-extremity prosthetic systems

r /FXQSPEVDUJPOBQQSPBDIFTXFSFEFWJTFEUPJODMVEF

 r Development of new sensor materials to measure pressure on the residual limb from the socket

 r *NQMFNFOUBUJPOPGBSFDFOUMZEFWFMPQFE%EJHJUBMNPEFMTZTUFNUPBEWBODFQSPTUIFUJDEFTJHO 

 manufacturing

 r An automated production technique to quickly braid the socket and to eliminate hand labor

r ManTech transitioned improved prosthetic technology to prosthetic component fabrication houses and 

 the sensor materials to clinical and research facilities

r %.45JOWFTUNFOUPG.

Impact:

r MJHIUFS
NPSFDPNGPSUBCMFTPDLFUT

r DPTUTBWJOHTPWFSUSBEJUJPOBMNFUIPETVTJOHBVUPNBUFECSBJEFS

r Faster production enables military prosthetists to spend more time on patient care and less time on 

 socket production

r -POHFSTPDLFUTFSWJDFMJGFMFBETUPMPXFSMJGFDZDMFDPTUT

ManTech Improves Durability and Comfort 

of Prosthetics and Orthotics for Wounded Warriors

Improved prosthetics restore Warrior’s quality of life

Defense-Wide Manufacturing Science and Technology, Navy ManTech, Advanced Technology 

International, Mentis Sciences, SensorTech, Clemson University, Georgia Institute of Technology

THRUST ONE

PROCESSING & FABRICATION

Improved prosthetics 

braiding automation 

enables wounded 

Warriors to return to 

an active lifestyle
Joint Defense M

(JDM

FY11 National Defense Authorization Act 

Establishes New Position

To ensure responsiveness to the Department’s current and 

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Deputy Assistant Secretary of Defense for Manufacturing 

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was appointed to this position. Integrating responsibilities 

for intensive assessment, industry engagement, and joint 

investments in manufacturing innovation, MIBP provides a 

holistic approach to defense supply chain health.

DoD ManTech Makes a Move

"TQBSUPGUIF/%""
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within the Office of the Secretary of Defense (OSD) and now 

reports to the Deputy Assistant Secretary of Defense for MIBP 

while maintaining close working relationships with its previous 

parent organization, the Office of the Assistant Secretary of 

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ManTech provides an essential factory-floor perspective, 

complementing MIBP’s other missions. With the responsibilities of 

developing technologies and processes that ensure the affordable 

and timely production and sustainment of defense systems, ManTech 

is a pivotal tool for MIBP and the Department.

JDMTP Continues Its Joint Coordination

The DoD ManTech Program continues to actively coordinate 

component program activities through the Joint Defense 

Manufacturing Technology Panel (JDMTP) that derives its 

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a process to effectively transition technology by identifying and prioritizing 

requirements for advanced manufacturing technologies and processes, conducting 

joint program planning, and developing joint strategies for the ManTech programs 

PGUIF"SNZ
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JDMTP

Page 8

New

Position

The MIBP and Its Role in

ManTech and the JDMTP
ManTech Panel

MTP)

JDMTP

Page 9

What About the Subpanels?

There are now four JDMTP Subpanels that review the projects within their respective 

technology portfolios, identify opportunities for collaboration, and provide input to the 

Principals on opportunities for future investment areas.

 METALS

The Metals Subpanel focuses on processing and fabrication technologies in the 

area of metals, ceramics, optical materials, certain metal matrix composites, 

ceramic matrix composites, and other materials of similar microstructure.

ELECTRONICS

5IF&MFDUSPOJDT4VCQBOFMGPDVTFTPONBOVGBDUVSJOHGPSFMFDUSPOJDTQBDLBHJOH

and assembly, electro-optics technologies, RF module technologies, power 

and energy sources, directed energy technologies, electromagnetic windows 

and domes, and lead free electronics.

COMPOSITES

5IF $PNQPTJUFT1SPDFTTJOH BOE 'BCSJDBUJPO4VCQBOFMGPDVTFT PO

the manufacturing and related technologies for the fabrication of parts 

and assemblies from composite materials, including polymer matrix 

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AME

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the shop floor” technologies and intelligent business practices that 

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encompasses the technologies, processes, and practices that foster 

rapid, effective assembly and superior execution of manufacturing 

enterprises across the life cycle. It involves a highly collaborative 

manufacturing environment among the multiple players in system 

development and production.

JDMTP Subpanel Technology Portfolios

4

Subpanels
DEFENSE-WIDE MANUFACTURING SCIENCE AND TECHNOLOGY (DMS&T)

THRUST ONE

PROCESSING & FABRICATION

The Challenge:

(MPCBM1PTJUJPOJOH4ZTUFN	(14
SFDFJWFSFMFDUSPOJDTNPEVMFTBSFUPPMBSHFUPJODPSQPSBUFJOUPTNBMMFSXFBQPOT

QMBUGPSNT4J[FDPOTUSBJOUTMFBEUPXBJWFSTUPBMMPXDPNNFSDJBM(14VTBHF.VMUJQMFNJMJUBSZTZTUFNTBSFGBJMJOH

UPCFOFàUGSPNFYJTUJOH(14DBQBCJMJUJFT

ManTech Response:

r %.45QBSUOFSFEXJUIUIF"NFSJDBO$PNQFUJUJWFOFTT*OTUJUVUF	"$*
BOE3PDLXFMM$PMMJOTUPBQQMZ 

 state-of-the-art microelectronics manufacturing and integration techniques to significantly reduce the 

 TJ[FPG(14DPNQPOFOUT

r 3FQBDLBHFEDJSDVJUGVODUJPOBMJUZJOUP3BEJP'SFRVFODZ	3'
BOE(14NPEVMFT

r -FWFSBHFEPUIFSQMBOOFEFGGPSUTGPSUIFVTFPG"QQMJDBUJPO4QFDJàD*OUFHSBUFE$JSDVJUT

r -JOLFEFNFSHJOHNJMJUBSZBQQMJDBUJPOT	FH
6ONBOOFE"FSJBM7FIJDMFT
NPSFDMPTFMZXJUI 

 TUBUFPGUIFBSUDPNNFSDJBMIBOEIFMENPCJMFFMFDUSPOJDT

r *ODPSQPSBUFEBO3'NPEVMF	XJUINJMJUBSZDPEFQSPDFTTJOHDBQBCJMJUJFT
JOUPB.PEFSOJ[FE(14

 6TFS&RVJQNFOUFNCFEEFEQSPEVDUGPSBUFDIOJDBMEFNPOTUSBUJPOQMBOOFEGPS':2

r %.45UPUBMJOWFTUNFOUPG.

Impact:

r $PNQMFUFEUIF(SPVOE#BTFE(143FDFJWFS"QQMJDBUJPO.PEVMF	(#(3".

EFNPOTUSBUJOHGVMM 

 QFSGPSNBODFBOEFYDFFEJOH$MBTTSFMJBCJMJUZSFRVJSFNFOUT

r "QQMJFEEFTJHOBEWBODFNFOUTPG%DIJQTUBDLJOHBOENJDSPQBTTJWFDPNQPOFOUT	SFTJTUPST
  

 DBQBDJUPST
UPBMMPXEFOTFSDJSDVJUMBZPVUTGPSUIF(#(3".5ZQF**	BTVSGBDFBSFBSFEVDUJPO


r *OTFSUFEB(14NPEVMFJOUP.JDSP(3".	(14SFDFJWFS

FOIBODJOHTJUVBUJPOBMBXBSFOFTTDBQBCJMJUJFT

r *OUFHSBUFEB(14NPEVMFJOUPBHVJEBODFTZTUFNXJUIBOUJKBNDBQBCJMJUJFTUPJNQSPWFQFSGPSNBODF

Effective performance through increased use of GPS in military systems

Defense-Wide Manufacturing Science and Technology, 

Navy ManTech, American Competitiveness Institute, Rockwell Collins

ManTech Improves GPS Usage Opportunities 

to Enhance Performance 

Page 10

 RF module

In-process image 

of a GPS module 
ARMY

The Challenge:

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JTUPSFQMBDFUIF508
)&--'*3&BOE."73*$,XJUIQMBOOFEQSPEVDUJPO

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seeker domes is zinc sulfide, but current processes involve hot isostatic pressing techniques and coating methods 

that are prohibitively expensive and time consuming to produce.

ManTech Response:

r An Army ManTech effort optimized the growth and processing parameters for zinc-sulfide, 

 specifically to produce material with better optical transmission and reduced cost

r "SNZ.BO5FDIJOWFTUNFOUXBT.
XJUI,PG45MFWFSBHFEGVOEJOH

Impact:

r Demonstrated a stronger, more affordable missile seeker dome that meets transmission 

 requirements for both infrared and semi-active laser systems

r *NQSPWFEZJFMEGSPNUPGPS[JODTVMàEFNJTTJMFTFFLFSEPNFT

r Reduced unit cost by 68%	,UP,


r 5SBOTJUJPOFEUPUIF"SNZT+PJOU"JSUP(SPVOE.JTTJMFQSPHSBN
BOEUIF/BWZT4NBMM%JBNFUFS

 Bomb II program

Cost benefit of $155.8M with an ROI of 19 to 1

Army RDECOM Aviation and Missile Research, Development and Engineering Center, 

Raytheon Missile Systems, ELCAN Optical Technologies

ManTech Delivers Affordable Missile Seeker Domes 

THRUST ONE

PROCESSING & FABRICATION

Page 11
NAVY

The Challenge:

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	7$4
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ManTech Response:

r Identified and classified pipe detail deliverables into specific classes based upon common 

 manufacturing and assembly characteristics 

r Product families assigned to specific work centers and process lanes to streamline pipe detail fabrication

r Identified equipment and tooling enhancements and developed business rules for the discrete 

 sequencing of joint to joint pipe fit-up and welding to provide pipe fitters and welders with written direction 

 for pipe detail weld sequencing, resulting in maximum usage of semi-automated welding technology

r Developed self-sufficient, cellular work centers and process lanes that support a more efficient 

 product flow through the pipe shop

r /BWZ.BO5FDIJOWFTUNFOUPG.

Impact:

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r "SFFOHJOFFSFEQSPUPUZQFXPSLDFOUFSGPSMBSHFEJBNFUFSQJQFXBTGVMMZGVODUJPOJOHJO+BOVBSZ

r 'VMMJNQMFNFOUBUJPOPGNBOVGBDUVSJOHDFMMTUIBUGPDVTPOBTQFDJàDMJOFPGQJQFQBDLBHFTBTTFNCMJFT 

 EFUBJMTEVSJOH

r Reduced cost and cycle time

ManTech Reducing VIRGINIA Class Submarine Costs 

with Process Reengineering

Estimated cost savings $1.2M per VCS hull

Navy ManTech, PEO Submarines, General Dynamics Electric Boat, Center for 

Naval Shipbuilding Technology, Institute for Manufacturing and Sustainment Technologies

THRUST TWO

MANUFACTURING ENTERPRISE

Reducing VCS costs by 

reengineering pipe shops

Page 12
AIR FORCE & DEFENSE LOGISTICS AGENCY

The Challenge:

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radiography is now widely available as a more affordable in-house inspection tool for metalcasting quality 

assessment, however, digital reference standards must be established to certify parts using this new technology.

ManTech Response:

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 $POTPSUJVN

UPQBWFUIFXBZGPS%JHJUBM3BEJPHSBQIZBOEUPEFWFMPQBOEHBJOBDDFQUBODFPG"45. 

 digital reference radiographic standards

r Air Force ManTech established digital equivalency to film by conducting Probability of Detection 

 (POD) studies at each casting supplier

r Air Force ManTech developed a guidelines document for digital radiography use that was supported 

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GPSBFSPTQBDF
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Impact:

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 	àMNTIFFUYTIFFUTJOàMNGPSBTJOHMFQBSU


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r Inspection data now stored electronically and digital standard guidelines available via ASTM

Saves $2M/year in radiographic inspection cost for DoD components

Air Force ManTech, DLA ManTech, AF Metals Affordability Initiative, University of Alabama – Birmingham, 

The Boeing Company, American Foundry Society, Steel Founders Society of America, Newport News Shipbuilding, 

ALCOA Howmet, Lockheed Martin, PCC, Structurals AMC & Advanced Technology International, ASTM International 

ManTech Leads Castings Industry Transition from 

Film to Digital Radiographic Inspection for Reduced Cost

THRUST TWO

MANUFACTURING ENTERPRISE

Page 13
INDUSTRIAL BASE INNOVATION FUND

The Challenge:

System requirements for microwave-based devices are increasing in operational frequencies and power, while 

decreasing in size and cost. Traditional microwave circuit board manufacturing methods cannot scale to these 

new frequency and power levels in small, lightweight packages.

ManTech Response:

r Implemented the PolyStrata® microfabrication process associated with sophisticated integrated 

 NJDSPXBWFDJSDVJUTBOENFUBMMJDDPNQPOFOUTUPTBUJTGZTVSHFSFRVJSFNFOUTGPS&8BOETBGFUZBOE 

 arming mechanisms for munitions

r /VWPUSPOJDTUFBNEFTJHOFEBOEFYFDVUFEFYQFSJNFOUTUPJODSFBTFZJFMEBOESFEVDFDPTUCZ

 r Optimzing the photopolymer processing

 r Revising the planarization chemistry and process

 r Improving electroplating speed and uniformity

r /VWPUSPOJDTJTXPSLJOHUPUSBOTJUJPONJDSPXBWFDPNQPOFOUTUP&"((SPXMFS/FYU(FOFSBUJPO 

 Jammer and safety and arming device for medium caliber munitions

Impact:

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BOE 

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Micro Components Developed for 

Next-Generation Jammer and Munitions

IBIF Investment of $998K and Industry Investment of $550K

2010 Industrial Base Innovation Fund, US Navy, Nuvotronics

THRUST FOUR

MFG. INFRASTRUCTURE

EA-18G with jammer pods

Page 14

PolyStrata Ka band

power amp prototype

PolyStrata frequency

scanned antenna

PolyStrata Recta-Coax

all copper air-dielectric 

transmission line

Air

$PQQFS

(Au plated)

Substrate

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The Industrial Base Innovation Fund (IBIF) is 2008-2010 Congressionally Directed funding executed by DLA on behalf of OSD, the OSD IP, the Military Services and the JDMTP. It 

ensures that investments are made to address defense industrial base shortfalls especially related to surge production requirements and diminishing sources of defense materials.
INDUSTRIAL BASE INNOVATION FUND

The Challenge:

When Air Force teams provide aero-medical evacuation services to our military and civilian personnel, they often 

require large and cumbersome avionics frequency converters and electrical extension cord systems to provide 

power from the aircraft to the medical equipment used during patient transport. Patients become “tethered” to the 

aircraft power systems with no simple method for patient transfer.

ManTech Response:

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CZ

 creating an improved, surge-capable fuel cell production line

r Jadoo Power made improvements in component tooling, reduced the cost of parts, improved assembly 

 and testing processes, increased throughput and decreased labor costs

r /FXQSPEVDUJPOMJOFNBZBMTPCFVTFEGPSPUIFSNJMJUBSZGVFMDFMMBQQMJDBUJPOTTVDIBTUBDUJDBMSBEJPT


 unmanned aerial vehicles, unmanned ground vehicles, sensors

Impact:

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UP


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r Improved first pass yields from 60% to 98%

r Resulting production line will increase throughput to meet surge requirements and improve quality 

 assurance and acceptance practices

IBIF Investment of $993,902

2010 Industrial Base Innovation Fund, Air Force Research Laboratory, Jadoo Power

Fuel Cell Production Capability Increased

to Meet Surge Requirements at Lower Cost

THRUST FOUR

MFG. INFRASTRUCTURE

Page 15

The Industrial Base Innovation Fund (IBIF) is 2008-2010 Congressionally Directed funding executed by DLA on behalf of OSD, the OSD IP, the Military Services and the JDMTP. It 

ensures that investments are made to address defense industrial base shortfalls especially related to surge production requirements and diminishing sources of defense materials.

PEPSAE unit

Fuel cell
INDUSTRIAL BASE INNOVATION FUND

The Challenge:

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 % EFTJHO NPEFMT BSF SFRVJSFE UP CF BCMF

to produce and replace aging components using today’s modern manufacturing facilities. Affordable modeling 

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may be inaccurate after years of design changes. 

ManTech Response:

r Rolls-Royce leveraged a previous Army ManTech program to develop a methodology for reverse 

 engineering legacy parts using a variety of optical scanning techniques

r An integrated product team was established including experts in design, manufacturing engineering, 

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 framework of generalized rules and tools

Impact:

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r Provides the Warfighter with critical spare parts for legacy weapons systems

ManTech Reduces Cost for the Preservation 

and Manufacturing of Legacy Components

IBIF Investment of $844K

Air Force ManTech, 2009 Industrial Base Innovation Fund, and Rolls-Royce Corporation

THRUST FOUR

MFG. INFRASTRUCTURE

Manual CAD Modeling

160–250 hrs

Page 16

The Industrial Base Innovation Fund (IBIF) is 2008-2010 Congressionally Directed funding executed by DLA on behalf of OSD, the OSD IP, the Military Services and the JDMTP. It 

ensures that investments are made to address defense industrial base shortfalls especially related to surge production requirements and diminishing sources of defense materials.

Optical-Based

Reverse Engineering

40 hrs

Legacy

Part
DoD ManTech - Did You Know?

r DoD ManTech developed the original numerically controlled machine tool and 

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 applications. 

r The DoD ManTech program developed the technology that became the 

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 forerunners of precision laser guided missiles and munitions.

r *OUIFT
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 thousands of obsolete microcircuits that support weapon systems still in 

 service. Use and mission benefits continue to expand today.

r *OUIFT
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 finishing for advanced military optics. The process is now also used by all 

 manufacturers of photolithographic optics.

r In the current decade, DoD ManTech:

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 for sensor systems

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 forces

 – Manufactured next generation of enhanced combat helmets to replace 

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 – Developed automated processes for lighter, durable and more comfortable 

 composite prosthetics 

 – Provided improved combat rations with high quality, safer, and surge- 

 capable production

 – Implemented higher power, longer duration batteries across weapon 

 systems

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 maritime construction for greater affordability
2011 Defense ManTech 

Achievement Award Nominations 

There were 7 nominations submitted through JDMTP Subpanels for the 2011 Defense ManTech 

Achievement Award. The awardees were announced at the Defense Manufacturing Conference. 

The JDMTP Principals would like to recognize these nominees for their efforts.

 Project Title Service

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* Use of Digital Radiography for Final Part Acceptance 

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 Structures Program Army

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 * Finalist
The Joint Defense Manufacturing Technology Panel (JDMTP) seeks to 

recognize and honor those individuals most responsible for outstanding 

technical accomplishments in achieving the vision of the Department of 

Defense (DoD) ManTech Program. That vision is to realize: 

“A responsive world-class manufacturing capability to affordably and rapidly 

meet Warfighter needs throughout the defense system life cycle.” 

To this end, the Defense Manufacturing Technology Achievement Award 

was established in the Fall of 1999.

AWARDEES

2010 – High Power, High Energy 

 Density Lithium-Ion Batteries

2010 – Seal Extrusion Development 

 and Demonstration (SEDD)

2010 – Weld Seam Facing and Back 

 Gouging

2009 – F-35 Inlet Duct Robotic Drilling

2009 – Low Cost Manufacturing 

 of Materials for Improved 

 Warfighter Protection

2008 – Laser-Welded Corrugated-Core 

 (LASCOR) Panel Evaluation

2008 – Low Observable Paints for 

 Aircraft

2007 – Lean Battery Initiative

2007 – Low Cost SiC-N Ceramic Tile

2007 – Translational Friction Stir 

 Welding

2006 – Uncooled Focal Plane Array 

 Producibility

2006 – Engine Rotor Life Extension

2005 – Large Aircraft Infrared 

 Countermeasures 

2005 – Large Marine Composite-to- 

 Steel Adhesive Joints 

2004 – Lean Depot Repair

2004 – Uniform Cannon Tube 

 Reshaping

2003 – Laser Additive Manufacturing

2003 – Laser Shock Peening

2002 – Composites Affordability 

 Initiative

2002 – Apparel Research Network

2001 – Enhanced Mfg. Processes 

 for Body Armor

2000 – Advanced Optics Manufacturing

2000 – Flexible Manufacturing of 

 Microwave Vacuum Devices

1999 – Advanced Fiber Placement
For Further Information

www.dodmantech.com