JAMCORP produces structural and component parts using Lattice Block Material (LBM) for use in the aerospace, shipbuilding, and precision measurement industries. Current production volumes range from 10 to 300 parts per year using off the shelf sand casting techniques and JAMCORP's patented coring system. For this solicitation JAMCORP proposes to: 1) Use current production processes and migrate them to the automotive industry by producing a prototype A-Arm, B-Pillar, and an optional LBM part in a configuration similar to that currently used by automotive manufacturers. 2) Provide prototype parts to the US Army and an auto manufacturer designated by the Program Manager for evaluation for suitability in the Future Army Ground Vehicle program. 3) Perform preliminary work to increase production capacity to several hundred parts per month in Phase 2. JAMCORP will accomplish this by re-engineering current processes to focus on the tooling level vice the product level for dual use items. 4) Conclusively demonstrate that all the production tooling costs can be absorbed in the application development stage In order to reduce total life cycle costs at a base material level, JAMCORP has developed Lattice Block Material (LBM). LBM is a new structural material system that uses the properties of a space frame to achieve strength, stiffness and low mass. LBM reduces a systems total life cycle costs due to several factors. Some of these factors come from reduced mass and some come from the use of innovative manufacturing methods. These factors are: 1) All the production tooling costs are absorbed in the application development stage 2) Less base material is needed for a given part and because less base material is used and discarded in the fabrication process used to produce that part. 3) A high percentage of system production cost is due to direct touch labor engaged in shaping and removing metal from bar stock and flat sheet. The LBM fabrication technique is sand casting, one of the least labor intensive fabrication methods available. 4) Current techniques rely on shop floor assemblers to attach numerous pieces together other using various fastening methods and hardware. LBM reduces these assembly costs by casting structural pieces as one component with an integrally cast skin over the lattice substrate. Since the space frame is composed of a one piece casting instead of mechanically fastened struts, much less assembly time is required to complete the structural part of the system. 5) The operating cost portion of LCC is reduced with LBM because there is less structural mass in the system and therefore less energy (and fuel) expended for transportation over the course of the system's life cycle. 6) Operating costs are also reduced by selecting materials that are inherently maintenance free such as Iconel or stainless steel.
