MQ-8B Drone Drive System Redesign

Elevate Systems provided critical engineering and design and sustainment support for the MQ- 8B Fire Scout—a Navy autonomous helicopter used for intelligence, surveillance, and reconnaissance (ISR) missions. A major challenge faced by the Navy was the obsolescence of the drive system’s rubber belt, a critical component ensuring the drone's reliable performance.

The original OEM belt provided over 400 flight hours, but once the Navy was no longer able to procure those belts, the replacement belts in use only lasted about 40 flight hours, significantly impacting fleet readiness and increasing maintenance burdens.

Our engineering team conducted a full analysis of the existing belt, including material composition testing, geometric analysis, and load capacity evaluation, to ensure an accurate redesign. Using advanced finite element analysis (FEA) and material optimization techniques, we developed an improved version of the belt with the objective of restoring the fleet to 400 flight-hour performance.

Elevate Systems then identified and qualified two new sources of manufacturing, providing the Navy with a stable and reliable supply chain for long-term sustainment. By leveraging our expertise in reverse engineering, technical data development, and manufacturing source qualification, we helped extend the operational lifecycle of the MQ-8B, ensuring continued mission effectiveness and reducing supply chain vulnerabilities.