Phase II Call for Innovative Defense-Related Dual-Purpose Technologies/Solutions with a Clear Air Force Stakeholder Need

Beacon Industries, Inc. proposes a scalable, field-deployable additive manufacturing (AM) solution for the Air Combat Command (ACC) to produce magnesium (Mg) alloy F-16 Accessory Drive Gearbox (ADG) components on demand at forward-deployed locations. This effort directly addresses the critical supply chain disruption caused by the 2024 shutdown of the U.S.’s largest magnesium alloy furnace and the absence of domestic alternatives. Leveraging Selective Laser Melting (SLM) and a fully developed Technical Data Package (TDP), Beacon’s solution allows for safe and repeatable production of Mg ADG parts by non-expert personnel in austere environments.Phase I established the technical feasibility of this approach by successfully reverse-engineering and printing Mg alloy test gears using SLM, achieving a relative density of 99.52% and a hardness of 115 HV, with mechanical properties exceeding those of traditional cast parts. The build achieved dimensional accuracy with a maximum deformation of only 5.4 µm and a simulated fatigue life of 380 million cycles. Phase II will transition this success into operational capability by delivering a validated TDP, including STL files, G-code/M-code, and safety protocols for use with high-purity argon shielding and controlled oxygen levels (<100 ppm) to mitigate fire and explosion risk.By decentralizing ADG component production, Beacon’s solution reduces lead time from months to days, enhances fleet readiness, and mitigates mission risk. It aligns with advanced materials and manufacturing modernization priorities, offering a transformative pathway to sustain independence and tactical agility for the U.S. Air Force. The proposed effort is practical, mature, and ready for near-term transition.