Munitions Handling Unit Compressor Re-manufacturing Initiative
Elevate Systems played a pivotal role in revitalizing mission-critical components for the B-1 Bomber's Munitions Handling Unit Compressors at Warner Robins Air Force Base. Faced with severe obsolescence issues and unavailable replacement parts, the Air Force was at risk of operational delays due to the inability to repair and sustain these vital assets. Elevate Systems leveraged its expertise in reverse engineering, additive manufacturing, and precision machining to develop high-quality, fully functional replacement components.
The air strainer, one of the most critical components of the compressor, had no viable source of supply. Elevate Systems stepped in to meticulously analyze, reverse engineer and model, and manufacture the air strainer using stainless steel additive manufacturing (3D printing). The newly fabricated part underwent a validation process, including dimensional inspections, material analysis, and functional testing, ensuring compliance with all engineering and performance specifications. Once approved by the Warner Robins Engineering Authority, the air strainer was successfully installed and tested on the compressor, proving its reliability in real-world operational conditions.
Beyond the air strainer, Elevate Systems performed full system assessments on additional compressor components, identifying further remanufacturing opportunities to extend the life of these essential systems. By combining reverse engineering with advanced manufacturing processes, we delivered cost-effective, rapidly deployable solutions, eliminating the need for costly and time-consuming legacy part searches.
As a result of this project, all refurbished compressors were promptly returned to service at Warner Robins AFB, ensuring mission readiness with minimal downtime. This success further underscores Elevate Systems’ role as a trusted sustainment partner for the U.S. Air Force, providing innovative engineering solutions to keep critical weapon system support equipment operational.
