Government
Since our beginning, Third Wave Systems has found great value in the joint research and development projects we have engaged in with various government and research organizations. Most projects have been initiated by Small Business Innovation Research awards. We have received the resources to connect with other experts and improve the capabilities and performance of our technology. In turn, the government receives innovative solutions to pressing problems that could not have been found otherwise. We have worked with the following groups: Air Force, National Aerospace Leadership Initiative, National Science Foundation, NAVAIR, Missile Defense Agency, Defense Logistics Agency, Army, and Defense Advanced Research Projects Agency.
Current Projects:
High Performance Machining of Titanium Bulkheads and Firewalls
NAVAIR SBIR Phase II
Program: V-22 Osprey
Objective: The overall goal is to demonstrate innovative, scalable high-performance machining processes the Navy needs for thin-web, large-pocket Ti-6Al-4V firewalls and bulkheads. The anticipated benefits of the program are the ability to fabricate unitized structures resulting in reduced labor costs, part count and improved quality while achieving desired weight requirements and fatigue life. Teaming with the prime contractor, we will develop monolithic designs that dramatically reduce cycle time and part count; and achieve cost and weight reductions needed for V-22.
Ductile Mode Machining of Ceramic Optics
MDA
Objective: This project focuses on the application of innovative diamond turning to eliminate grinding, lapping, and polishing in the production of high-quality optic surfaces
Army Future Combat System (FCS)
Congressional Appropriation
Objective: The goal is to dramatically reduce the cycle time of the large-structure components that serve as armor for the FCS
Residual Stress and Part Distortion
National Science Foundation
Objective: Through this SBIR project TWS continues to develop and validate a three-dimensional finite element modeling capability to predict the final state of stress and distortion for a complete workpiece part prior to any manufacture. Residual stress has high economic impact to industry since the cost of manufacture is incurred prior to any measurement or detection. This project demonstrates an integrated approach to predicting residual stress effects upon completely manufactured parts. Applications include large, thin walled aerospace parts (such as wing spars), structural components, and parts susceptible to high rates of fatigue (rotor wing hubs and load carrying parts, spindles, structural, and powertrain components). The automotive sector, primarily within engine block manufacture, piston liners, bearings, spindles, and hard turning applications, could also benefit from this technology.
Low-cost Machining of Integrally Bladed Rotors (IBR) (picture of F-35)
Air Force SBIR
Program: F-135
Objective: The goal is to use Third Wave Systems’ high-speed machining technologies to deliver the affordable manufacturing of titanium and nickel IBRs, with improved surface finish. The program goal of an immediate 45 percent cost reduction can be attained without the need for capital equipment investments.
Drilling of Composite Materials
Defense Logistics Agency
Objective: In this project, modeling composite and composite-metal stackup drilling processes will be investigated. The goal is to provide more information than is available through trial-and-error testing in order to improve drill life and hole quality.
Affordable Machining Program
Metals Affordability Initiative
Objective: The purpose of AMP is to develop and implement analytical tools and advanced machining technologies to enable lower cost fabrication of machined aerospace components. The goal is to develop and implement the most affordable methods of fabricating high-accuracy machined components, and to establish component designs and assembly approaches enabled by this precision machining capability. Using this integrated design and manufacturing strategy, AMP hopes to achieve aerospace structures exhibiting improved quality and performance with up to a 50 percent cost savings.