Military-electronics technology has long trended toward achieving more functionality and performance in smaller packages. The ways in which electronic technologies are applied may change, but that trend for smaller and lighter electronic devices and systems remains. For companies faced with supplying electronic components and equipment for military applications, most innovations focus on saving size, power, weight, and, of course, cost.

At the highest levels, military-electronics technology is driven by large programs, and each of the branches of the United States military has invested in major, "pet" programs aimed at modernization and/or future capabilities. The US Army's appropriately named Future Combat Systems (FCS) program (www.army.mil/fcs), for example, represents one of the most ambitious developmental programs in US military history. Often referred to as a "system of systems," FCS is based on a vision of a robotic battlefield, using unmanned aerial vehicles (UAVs), unmanned ground vehicles (UGVs) and robot soldiers, and a sophisiticated wireless communications network for communications and control among humans with remote controls and their robotic counterparts. Under the stewardship of prime contractor, The Boeing Co. (www.boeing.com), and partner Science Applications International Corporation (SAIC), acting as Lead Systems Integrator (LSI), the FCS program has so far met all major milestones in developing this next-generation electronic army.

The FCS System of Systems Functional Review, for example, conducted about two years ago, lasted for five days and involved more than 35 briefings and dozens of demonstrations to attendees who included members of the US Army, Department of Defense (DoD), and the Government Accountability Office (GAO). The review included more than 11,000 system-of-systems engineering requirements derived and allocated through a rigorous systems engineering process. The review, conducted more than two years into the FCS program, was part of the FCS Systems Development and Demonstration Contact, valued at $20.9 billion. Since the review, the FCS program has undergone several successful field experiments and demonstrations, to the great satisfaction of US Army attendees and participants involved with various aspects of FCS electronic systems. The spinout of FCS capabilities is expected to begin in 2008, including networking, unattended munitions, sensors, and robotic systems, with the first FCS Unit of Action (larger-scale system) scheduled for release in 2014. The Unit of Action includes 18 manned and unmanned ground and air platforms, tied together by wireless network.

Most recently, Boeing and SAIC (www.saic.com) have selected Elgin, OK as a principal site for FCS Manned Ground Vehicle (MGV) integration and assembly work. Partner BAE Systems (www.baesystems.com) will construct and manage a 150,000-sq.-ft. facilityat the Ft. Sill Industrial Park in Elgin. The facility will initially house production integration and assembly activities for the Non-Line-of-Sight Cannon (NLOS-C) initial production platform, the first of eight FCS vehicle variants. Completion of the new facility is anticipated in 2009. The FCS MGVs are being developed in partnership with BAE Systems and General Dynamics (www.generaldynamics.com) with the intent of dramatically enhancing soldier survivability. The MGVs feature an integrated hybrid-electric propulsion system, the first use of such technology in operational Army ground combat vehicles. The first use of the hybrid electric drive technology will be in the NLOS-C.

Looking forward, Boeing and the US Joint Forces Command (USJFCOM) have signed a three-year Cooperative Research and Development Agreement (CRADA) to analyze current, emerging, and future joint warfighting concepts and capabilities. The analysis is in concert with the USJFCOM's Joint Innovation and Experimentation Directorate (Suffolk, VA), and will employ computer modeling, simulation, and analysis with virtual and live experiments to evaluate the US DoD's joint concepts and enabling capabilities. Boeing Advanced Systems' AMSE division will lead the company's efforts under the CRADA.

In addition to its sophisticated networking capabilities, the FCS relies on advanced robotics technologies to keep human soldiers out of harm's way. Boeing recently signed a teaming agreement with robotics specialist iRobot Corp. (www.irobot.com) to develop and deliver a next-generation Small Unmanned Ground Vehicle (SUGV) for military, civil, and commercial applications. The SUGV is designed to be less than 30 lbs. and enable users to remotely conduct reconnaissance and intelligence-gathering operations. The agreement calls for the use of commercial-off-the-shelf (COTS) technology to the greatest extent possible in the development of the SUGV, which is expected to be in production by 2008.

The developmental SUGV Early will be a smaller, lighter version of iRobot's PackBot^® robot, which is battle tested in Iraq and Afghanistan for safely disarming improvised explosive devices (IEDs) as well as searching buildings, tunnels, and caves for hostile forces. According to Vice Admiral Joe Dyer (U.S. Navy, Ret.), president of iRobot Government & Industrial Robots, "By teaming with Boeing, we can leverage their system-of-system capabilities and global marketing strength to quickly get these life-saving robots into the hands of our troops, first responders and allies worldwide."

Boeing and iRobot will jointly market the new SUGV Early robot. Boeing will also contribute expertise in systems integration, large-volume production, and global marketing, while iRobot will design, develop, and manufacture the robot using its proven experience with the iRobot PackBot and its development work on the FCS program. Dennis Muilenburg, vice president and general manager for Boeing Combat Systems, says "We see ground robots as a major new growth market and iRobot, as the industry leader in this field, is our partner of choice to bring new robot technology to market." More than 900 iRobot PackBot robots have been delivered to a broad range of military and civilian customers worldwide, for operations that have included life-saving missions in Iraq and Afghanistan. iRobot recently announced a delivery order from the US Navy to build additional bomb-disposal robots for shipment to the US forces overseas. The $14 million award from the Naval Sea Systems Command (NAVSEA) calls for 101 iRobot PackBot^® Man Transportable Robotic System (MTRS) robots, plus spare parts to repair robots in the field. iRobot shipped the initial lot of PackBot robots for this order in late March 2007, and the company expects to deliver the remaining robots pursuant to this delivery order before the end of this year. Under the terms of the previously existing Indefinite-Delivery/Indefinite-Quantity (IDIQ) contract, the military could order up to the full $264 million value in robots, spare parts, training, and repair services. The US military's MTRS program has requirements for as many as 1200 robots through 2012.

The DD(G) will feature a revolutionary gun called the Advanced Gun System (AGS), which can hurl shells at distances to 100 nautical miles with high accuracy. The AGS will fire rocket-assisted long-range rounds guided by the Global Positioning System (GPS). These Long Range Land Attack Projectiles (LRLAPs) can be fired at a rate of 12 rounds per minute. The fully automated gun and magazine will employ a water-cooled barrel to sustain the high firing rate without overheating.

The CG(X) will share a common propulsion system with the DD(G) but a stealthier hull form. The hull form will contain an integrated all-electric power system more efficient than current propulsion systems with more power capacity for future weapons systems. Like the DD(G), the CG(X) will be designed for reduced crew size and operating and support costs. In support of both ships, a new generation of air-defense radar systems is under development to counter low radar-cross-section (RCS) threats at extended ranges. The CG(X) will be able to detect, track, and engage ballistic missiles at long range and outside of the atmosphere. Additionally, the US Navy's Combined Engagement Concept (CEC) intends to integrate the defenses of naval forces at sea by combining sensor information from ships and aircraft within 2500 square miles. The US Air Force and Marine Corps are developing similar network-centric systems.

Because the US Navy is committed to cost reductions on the Cruiser Modernization Program, it is seeking technology partners capable of "leaps of innovation" that will help achieve performance targets at reduced weight, size, and cost. One microwave company involved with applying innovative technology to the program is Merrimac Industries (www.merrimacinds.com) with its advanced Multi-Mix^® multilayer circuit technology. Based on the use of fusion-bonded circuit-board layers that can hold embedded active and passive components, and handle high power levels through millimeter-wave frequencies, Multi-Mix^® has been applied to several multifunction modules, including an Integrated Module used as part of the advanced radar system aboard the DD(G). Compared to traditional RF/microwave circuit technologies, the Multi-Mix^® module is helping to remove about 3000 lbs. per ship. The company also supplies a highly integrated Multi-Mix^® beamforming assembly for the CG(X) cruiser.

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