WC-135 Constant Phoenix Support

Elevate Systems supports the Cyber and Crypto Systems Division on the WC-135 Constant Phoenix where they remanufacture specialized compressors for a unique air collection mission.

One of our key contributions has been the remanufacture of the WC-135 compressor assembly, which is a critical component of the Whole Air Collection System (WACS). Faced with obsolete and non-procurable parts, Elevate Systems successfully conducted a Teardown, Test, and Evaluation (TT&E) of existing compressor units, identifying necessary refurbishments and component replacements. Through precision machining, component requalification, and meticulous assembly, we were able to restore over 70 compressor assets, taking them from zero available spares to a surplus inventory of over 40 units.

Additionally, Elevate Systems led the reverse engineering and fabrication of the WC-135 sphere casements, critical for the containment and operational integrity of the WACS. These components required high-precision measurement, material analysis, and complex geometric modeling to develop unrestricted technical data packages. Using advanced 3D scanning, CAD modeling, and manufacturing techniques, we were able to produce new sphere casements that met or exceeded original design specifications, ensuring full compatibility with the aircraft’s systems.

Through these efforts, Elevate Systems has reduced lead times, mitigated obsolescence risks, and delivered high-quality engineering solutions to sustain the WC-135 fleet. Our work underscores our ability to extend the life cycle of aging systems while maintaining the highest levels of performance and reliability.