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Precision Tooling & Custom Manufacturing for HyFly Missile Program

The HyFly program was initiated in 2002 by DARPA (Defense Advanced Research Projects Agency) and the U.S. Navy's ONR (Office of Naval Research) to develop and test a demonstrator for a hypersonic Mach 6+ ramjet-powered cruise missile. Prime contractor for the HyFly missile was Boeing, while Aerojet built the sustainer engine. The vehicle was air-launched from an F-15E aircraft, and is accelerated to ramjet ignition speed by a solid-propellant rocket booster.

The sustainer engine of HyFly is a so-called dual-combustion ramjet (DCR). This complex experimental engine was constructed of carbon/carbon composite with ceramic conversion coating. Lx3 involvement in this project spanned 6 years and pertained to Ramjet sustainer engine.

Lx3’s involvement included:
  • Manufacturing of composite layup tooling for various components.
  • Manufacturing of assembly fixtures and tools.
  • Design and manufacturing of machining fixtures.
  • Developing machining program for carbon/carbon components.
  • CNC machining and inspection of carbon/carbon components.


Our CNC lathes and mills were able to meet ultra-precision tolerances, down to +/- 0.0003". We additionally polished the surface of all layup tooling, performed CMM and dimensional inspections on all tooling and components, and shipped the finished items to our client's facility in Arlington, Texas.






Precision Tooling & Custom Manufacturing for HyFly Missile Program Project Highlights

Project Description
LX3 was involved in the development and manufacturing of the sustainer engine for the HyFly missile program. LX3 provided extensive precision layup and assembly tooling for project. CNC machining was also performed on carbon/carbon flight components as needed.

The HyFly program was initiated in 2002 by DARPA (Defense Advanced Research Projects Agency) and the U.S. Navy's ONR (Office of Naval Research) to develop and test a demonstrator for a hypersonic Mach 6+ ramjet-powered cruise missile. Prime contractor for the HyFly missile is Boeing, while Aerojet builds the sustainer engine. The vehicle is air-launched from an F-15E aircraft, and is accelerated to ramjet ignition speed by a solid-propellant rocket booster.

The sustainer engine of HyFly is a so-called dual-combustion ramjet (DCR). This complex experimental engine was constructed of carbon/carbon composite with ceramic conversion coating.

Capabilities Applied/Processes
Manufacturing
  • Composite Layup Tooling
  • Assembly Fixtures & Tools
  • Machining fixtures
  • Graphite restraints
CNC Programming
  • All layup tooling, assembly fixtures, and restraints
  • Develop machining programs for Carbon/Carbon components as required.
CNC Machining
  • All layup tooling, assembly fixtures and restraints
  • Machine carbon/carbon components as required
Inspection
CMM inspection of all tooling and carbon/carbon parts machined

Equipment Used to Manufacture Tooling
CNC Lathe
CNC Mill

Tightest Tolerances
+/- 0.0003"

Material Used
Composite Layup Tooling:
Ren Tooling Board
6061 Aluminum

Assembly and Machining Fixtures:
6061 aluminum
Tool steel

Finished Components:
Carbon/Carbon composite

Finish
Polished surface finish on all layup tooling.

In Process Testing/Inspection Performed
CMM and dimensional inspection of all tooling and components

Manufacturing Turnaround Time
Project spanned 7 years

Industry for Use
Defense/Military

Standards Met
Customer Specifications

Delivery Location
Arlington, TX

Product Name
Precision Tooling & Machining of HyFly Missile Components



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