PORT HUENEME, Calif. – It was just a small part, weighing only 16 pounds, but the absence of this component grounded a fleet of critical vehicles for the warfighter. The military needed a solution—and it needed it fast.
Enter the team of experts at Naval Facilities Engineering and Expeditionary Warfare Center’s (EXWC) Expeditionary Department, who created custom D-Ring tie-downs from concept to production in four months. This process, if done through the traditional means of contracting and using outside vendors, could have taken two years.
"This effort perfectly demonstrates the value of expeditionary maintenance. By bridging the gap between operational vehicle modifications and strict aviation safety requirements, EXWC’s Expeditionary Department delivered a rapid, engineered solution that directly enhanced fleet readiness and lethality," said Expeditionary Technical Department Head Capt. Adam Perrins.
Engineer Abe Sikes designed the D-Rings, and fabrication occurred at the Expeditionary Maintenance Depot – Southwest (EMD-SW) in Port Hueneme through the work of Inspector Gerald Judd, Welder Jeremy Handel, Welder Martin Diazconti, and Shop Leaderman Joshua Zarco.
These D-Ring tie-downs resolved a critical air transportability gap for Medium Service Support Vehicles (MSSVs), restoring rapid deployment capabilities for Explosive Ordnance Disposal Expeditionary Support Units (EOD ESU) 1 and 2.
Solution Needed
EOD ESU’s Medium Service Support Vehicles (MSSVs) did not have the tie-down points required in their certification for Air Force transport.
The Air Force requires an Air Transportability Test Loading Activity (ATTLA) certification to fly vehicles on military aircraft. The existing ATTLA certification for the MSSV fleet covered a version with D-Ring tie-downs and no recovery winch.
However, the specific MSSVs fielded by the EOD ESUs had been operationally modified to include recovery winches but did not have the necessary D-Rings. Without these certified tie-down points, the vehicles could not be properly secured to the aircraft deck, grounding the fleet and degrading the units' expeditionary capabilities.
Rapid Action, Precision Engineering
Instead of waiting for a lengthy procurement process for specialized replacement parts, the Expeditionary Department immediately got to work, opting for in-house fabrication to address this critical gap.
The Expeditionary Department created a solution that was quick, precise, and structurally sound to meet the stringent ATTLA stress requirements.
Utilizing a Flow Water Jet Mach 200, which operates at a staggering 60,000 psi, EMD-SW technicians precision-cut the required components from solid steel. They manufactured 60 custom D-Rings, specifically engineered to integrate with the winch-modified MSSVs.
The Outcome: Warfighters back in the fight
The rapid manufacturing of these custom steel D-Rings allowed the modified MSSVs to get back into compliance with the ATTLA certification.
By bridging the gap between the operational modifications and the strict aviation safety requirements, EMD-SW's swift action restored the critical air transport capabilities of EOD ESU 1 and 2, ensuring the warfighters have what they need for the fight and can deploy globally at a moment's notice.