Replacing Obsolescence
project name

Replacing Obsolescence

Supporting Military Maintenance Repair and Overhaul (MRO)


Providing engineering and support for an obsolete foreign military actuator.

CaseStudy3Problem Statement
An international customer under a foreign military sales (FMS) effort needed a replacement actuator which the original equipment manufacturer (OEM) had deemed obsolete. The actuator is used to deploy and retract an electro-optical/infrared (EO/IR) turret assembly during in-flight operations in specially modified aircraft for that country’s Coast Guard. Since the part was obsolete and no larger a business focus for the OEM, repair and support of the part was cost-prohibitive and ultimately discontinuing.

The customer weighed options including elimination of the mission profile, aircraft replacement, redesign and requalification of an entire structural modification, or identifying a new source of supply for the actuator – a partner that could design and qualify a replacement product. The FMS client contacted Ingenium Aerospace to solve the linear electromechanical actuator (EMA) shortage and obsolescence problem.

The long stroke, several thousand pound stall force EMA operated at 115VAC/400Hz electrical power and was completely redesigned and optimized by Ingenium Aerospace. A proposal was available for the international customer within weeks of receipt of the request for proposal. Ingenium provided the finite element analysis (FEA), dynamic, reliability, endurance life, and thermal models as well as an integrated master schedule to efficiently manage the project.

Results & Outcome
The EMA design was approved by the customer as was Ingenium’s manufacturing plan for the engineering, qualification, manufacturing & development phase. The design has been completed and Ingenium Aerospace is ready to proceed upon final budget approval.