HH-60H Seahawk Gatling Gun Mount Reverse Engineering

Elevate Systems successfully executed a reverse engineering and sustainment effort for the port and starboard GAU-17 gun mount assemblies used on the HH-60H Seahawk. The GAU- 17, a critical rotary machine gun system, is an essential component of the Seahawk’s defensive armament, providing suppressive fire capabilities during combat and rescue operations.

However, with the original mounts becoming obsolete and no longer supported by the OEM, the U.S. Navy required a solution to sustain the platform and ensure continued mission readiness. Elevate Systems performed detailed metrology, dimensional analysis, and material characterization of the existing mounts to create a comprehensive Technical Data Package (TDP). This effort included developing high-fidelity 3D CAD models, 2D engineering drawings, and a full material analysis report, ensuring future manufacturability and compatibility with the aircraft’s structural and operational requirements.

To validate our reverse-engineered design, we conducted Finite Element Analysis (FEA) to assess structural integrity under operational loads, ensuring the redesigned mounts would meet or exceed original performance specifications. Additionally, we identified and qualified new sources of manufacture to support long-term sustainment, allowing the Navy to procure these critical components without reliance on outdated OEM supply chains.

By leveraging our expertise in reverse engineering, additive manufacturing, and sustainment engineering, Elevate Systems provided a cost-effective and timely solution to restore supportability for the HH-60H GAU-17 gun mounts, ensuring continued warfighter capability and fleet readiness.