Re-Engineering the Past: The B-2 Spirit Project

Elevate Systems, a pioneer in multidisciplinary engineering, made a significant impact on the B-2 Spirit bomber project, demonstrating its expertise in reverse engineering and innovative design. The project was to reverse engineer both the load and the sink heat exchangers and provide zero time assets back to the Air Force. Other sources were available to complete this work but projected a period of performance of 2-4 years and costs in excess of $20M.

The B-2 Spirit, a strategic asset for the U.S. Air Force, faced significant challenges. The lack of technical data and difficulty re-procuring assets from the mid to late 80s posed a serious threat to the availability and readiness of these aircraft. It was reported that some of the assets were not airworthy and would not be until this project was completed.

Stepping up to the challenge, Elevate Systems took a strategic approach. Leveraging their expertise in reverse engineering, the team meticulously analyzed the existing components, and completed the metrology which resulted in the creation of 3D models allowing for the creation of 2D Drawings needed to provide a process to disassemble, recore and reassemble and test the zero time assets provided. Concurrently, they embarked on the identification and qualification of new manufacturing sources to ensure that every recreated component would meet the rigorous standards of the U.S. Air Force.

The result was a resounding success. Through their efforts, Elevate Systems achieved a significant reduction in the projected timeline and cost for the project. The Air Force saved an estimated two and a half years and approximately $18 million, swiftly getting their planes back up in the air.

Today, the Air Force has a new source for remanufacturing the load and sink heat exchangers at a significantly lower cost and greatly reduced timeline.

The B-2 Spirit project stands as a testament to Elevate Systems' commitment to innovative engineering solutions. Their unique blend of skills, spanning from reverse engineering to modern design, enabled them to solve a complex problem efficiently and effectively. It's a shining example of how the past and the future can intertwine in the field of engineering, ultimately leading to remarkable results.