Field Optimized Advanced Manufacturing (FOAM) Pod Full Suite (FS)

The Field Optimized Advanced Manufacturing (FOAM) Pod – Full Suite proposed development by Dynovas and AMfg Labs aims to address the U.S. Army's urgent need for an expeditionary manufacturing solution for complex Class IX repair parts in tactical environments. This solution responds to SBIR Topic A244-070, which identifies the challenges in providing soldiers with ad hoc capabilities to design, fabricate, assemble, and ensure the quality of repair parts for critical wheeled vehicles, such as Humvees and FMTVs.  The FOAM Pod – Full Suite solution integrates advanced manufacturing technologies, quality assurance tools, and secure data management systems into a cohesive mobile unit that soldiers with minimal training can operate. The proposed system builds upon Dynovas' prior high TRL/MRL manufacturing platform funded by the Defense Logistics Agency, which resulted in mobile production pods for metals and composite parts. This current proposed project will enhance the capability by developing a modular system of three to five 20-foot expandable shelters, each housing specific functionalities. These functionalities include a Design & Quality Command Pod, an Additive Manufacturing Pod for metals and polymers, a Machining Pod, a Composites Production Pod, and a Finishing/Coating Pod, and target manufacturing of engine cooling fan for wheeled vehicles for ARMY utilized active vehicles. Validation for the FOAM Pod system will occur over Phase I and II through proof-of-concept hardware for an engine cooling fan component, targeting a TRL 5 (Phase I) for relevant operating conditions. Dynovas aims to demonstrate the feasibility of producing engine cooling fans and related components with the proposed pods, meeting Army standards and environmental specifications. Testing will involve design iteration, component testing, and feedback from end-users in the Army to refine the pod's and manufactured hardware's performance. This modular and redundant design promises efficient, near-point-of-need manufacturing, providing a responsive and self-contained system that aligns with Army modernization priorities. Secure data handling through Aura Technologies' TrustedDM ensures safe transmission of technical data across tactical environments. The FOAM Pod's modularity allows scalability and adaptability to various deployment needs, paving the way for broader adoption in the Army’s supply chain.