SBIR-STTR Award

Dynovas Composite Telescoping Shoring (CTS) is 2-sailor installable in 15 min or less per shoring, resistant to the marine environment, pre-tension stabilized for up to Sea State 8, >50% lower weight than timber, and height and length modular from 7.5 to 15 ft. Each benefit is included in a single self-contained assembly requiring no separate tools for install. The CTS solution is a direct drop-in for the obsolete timber shoring and does not impact the existing lashing solution, enabling ease of implementation into the fleet. The CTS design focuses on: Structural integrity (fire retardant, marine grade fiber glass composites are stronger per pound than timber shoring) Lightweight for easy handling and install (open section composite structure requires only 15 minutes to install at each location) Reliable for all positions and in all sea-states (modular telescoping construction and pretensioned, rigid physical locks with shock dampening) Rapid install, disassembly, and storing (simple, robust operation of one self-contained assembly with no external tools) Low maintenance and serviceable while underway (simple, marine grade systems with common parts to other shipboard systems) Low-cost production via automated additive manufacturing, CNC, and composite manufacturing processes The overarching technical objectives of the Composite Telescoping Shoring (CTS) development is a lightweight, two-man portable, adaptable, reusable, low-cost shoring system. The shoring system will initially be specifically designed for the LCU, but the modularity of the design and the commonality of the intended hardware will make scaling, reconfiguring, and redeploying the CTS to other applications easy. In Phase I, Dynovas will produce a proof-of-concept design with detailed analysis of the system structure and kinematics. Additionally, Dynovas will produce a subscale proof-of-concept CTS utilizing automated composite manufacturing techniques (e.g., filament winding). The subscale article will be assembled with representative mechanisms and demonstrated operationally and structurally. The structural demonstration will include compressive testing to validate strength and buckling resistance of the shoring concept. The Phase I base Technical Objectives were selected to validate the CTS via design, analysis, and testing. The validated CTS concept in the Phase I base program reduces risk and sets the foundation for accelerated development, qualification testing, and deployment in Phase II and beyond. The Phase I Option Technical Objectives were established to initiate the transition from the Phase I proof-of-concept to the Phase II prototype. As such, the option focuses heavily on low cost manufacturing development, component weight optimization, and long lead materials, environmental test planning, and structural test planning.

Benefit:
Anticipated benefits of the CTS include: The CTS is designed as a single assembly with integrated, serviceable hardware The pretensioned telescoping system of the CTS enables install of each assembly in an estimated

Keywords:
LHD, LHD, multi-use, lcu, Composite, Shoring, Telescoping, LHA, Corrosion resistant

In this Phase II program, Dynovas will advance the MRL and TRL of the Composite Telescoping Shoring (CTS) to 6 via prototype design, build, and test. The TRL/MRL 6 demonstration will validate the anticipated benefits of the system. The CTS can enable the stowage of a Landing Craft Unit (LCU) in the well decks of Amphibious ships in less than 120 minutes, cost less than 50% of the lifetime use of timber shoring (saving the fleet $130M+ over a 20 year usage span), provide modularity from 7.5-15ft lengths, and adapt to remain in positive control of the LCU for sea states as high as 8. Furthermore, the CTS can be installed by 2-sailors (with the support of a well deck fork-lift), will weigh less than 200 lbs (30% of the weight of timber currently required), and is entirely serviceable while on deployment, home ported, or during ship/boat maintenance cycles. The CTS delivers the same general functionality of the timber shoring, namely starboard-port swaying restraint, but has several features that increase sailor safety, mission tempo, equipment safety, longevity, and decreases lifetime use costs. In Phase I, the CTS was demonstrated at TRL 3 via proof-of-concept against the highest priority requirements on the system. The highest priority requirements include securing the 448 long ton LCU 1700 in sea states up to 8 (~83 kips per shore), be compatible with the ship/LCU flexing, be operationally equivalent from 7.5-15 ft distances, minimize weight, minimize stowage volume, and minimize install personnel/time required. This Phase II SBIR is split into a Base Program and two (2) Options. The Base Program is heavily focused on system design, initial operational prototype build (TRL 5), sailor feedback, and full system manufacturing planning (including preliminary manufacturing tooling design). The results of the Base will be used to finalize the full structural design and build in Option 1 (including final tooling design and procurement). In addition to assembling the TRL 6 prototype in Option 1 in a production relevant environment (MRL 6), preliminary test planning will be complete. Option 2 will complete the test plan, including all fixture design, and focus on operational, environmental, and structural testing of the CTS to validate TRL 6. The Dynovas team possesses the necessary equipment, capabilities, and expertise to execute on this SBIR program such that all funds can go towards TRL and MRL maturation. Following technology development, Dynovas is prepared to lead the CTS system through technology maturation, qualification, Low-Rate Initial Production (LRIP), and Full Rate Production (FRP). Dynovas will internally manufacture the composite tubes, outsource metallic details to the US industrial base, internally assemble the CTS systems, and perform a hybrid execution of qualification and acceptance testing. Dynovas current equipment, facilities, partnerships, and capital investment plans exist and outpace the scheduled need for production ramp-up.

Benefit:
The Composite Telescoping Shoring (CTS) system delivers the following benefits to the Navy: Require less than 50% of personnel required with timber to restrain an LCU Install all locations of the CTS around an LCU in less than 33% of the time of timber Weigh 30% of the weight of the timber (less than 200 lbs each assembly) One self-contained, adjustable assembly Projected 20-year life Universal to the fleet of LCU and amphibious warcraft Dynovas estimates that successful delivery and commercialization of the CTS will occur after achieving TRL/MRL 7-8 (~2025). Delivery to the fleet will be at a rate of ~12 per ship per LCU (PMS-317). The Navy amphibious warfare ship fleet (PMS-377) includes the LSD-41 Class (3 LCU/ship), LHD-1 Class (2 LCU/ship), LSD-49 Class (1 LCU/ship), and the LPD-17 Class (1 LCU/ship). If each of the 29+ ships are fully outfitted with the number of CTS required for the maximum number of LCU, a total of 500+ CTS will be produced. At a rate of twelve (12) CTS per month, Dynovas can have the entire fleet outfitted in less than four (4) years. The CTS development and production plan delivers two paths towards a Return on Investment (ROI) over its competition (the incumbent timber shoring). In summary, the crew reduction from six (6) to two (2) will save the Navy ~ $200k/yr per ship, or $5.8M/yr across the fleet. An ROI on the SBIR development costs of 2 will be realized in the first year and over 50 during the 20-year life of the system. The CTS will also deliver an ROI of 2-3 over the cost of the non-reusable timber over the life of the system. The non-financial ROIs include increased sailor safety and increased mission tempo. The successful development and market insertion of CTS for the Navy will open doors to a much larger market for reusable, long life, modular, high strength shoring. Aside from the Navy, modular, high strength shoring provides capability to the commercial industry including cargo ships, tankers, piers, dry docks, etc. With success of the SBIR program, Dynovas will also market the CTS to these commercial markets.

Keywords:
Composite, Shoring, Lifecycle management, amphibious warcraft, LHA, LHD, Land craft unit, maintenance