Brighton Cromwell, LLC — Department of Defense SBIR Phase II: DLA181-006

Description

ABSTRACT AND DEVELOPMENT PLAN: In our current contract SP4701-20-C-0014 (Phase II), Brighton Cromwell generated the documentation to improve product availability and increase competition through the development of Small Business eligible manufacturing for coaxial cable assemblies for form, fit and function equivalency with NSN 6145-01-123-7019. There is no military qualified product for this coaxial cable assembly. Under our current contract, BCTC identified two commercial Suppliers currently supplying 1-5/8 50 Ohm coax that most closely matched the requirements for NSN 6145-01-123-7019, and identified all testing required to qualify this cable in accordance with USAF aviation regulation, standards (Boeing Specification 10-22453-2) requirements. After identifying all testing requirements and fixturing demands, BCTC developed a DVP&R (Design Verification Plan and Report) outlining all the testing required to qualify these parts. Also, BCTC generated a detailed program schedule and over-arching test strategy to support the qualification of both commercial products. This test strategy evaluates cables from two different manufacturers. Both manufacturers' products satisfy BAA requirements. 88% of CommScope cable is manufactured in Catawba, NC, with the remaining 12% (inner copper conductor) manufactured in Germany. The CommScope coax is produced with a modern foam core dielectric and does not utilize adhesive to bond the inner conductor. CommScope manufactures this size cable every year. Superior Essex shall supply new old stock manufactured to the legacy Andrew Corp requirements, and originated from the original Orland Park, IL facility. This survivor stock is the last that exists. Superior Essex manufactures all their coax cable in South Korea, and they will never produce this old style of 1-5/8" 50 Ohm cable again. This proposal is for the testing and qualifying of these two cables to determine acceptability to meet the performance criteria established in the Boeing specification 10-22453-2 and the additional requirements established by Brighton Cromwell LLC DVP&R and in agreement with the Air Force team.  The following figure identifies where the qualification of the product shall occur and by whom.