Deep Purple brings home team excellence award

  • Published
  • By John Ingle
  • 82nd Training Wing Public Affairs
SHEPPARD AIR FORCE BASE, Texas --  The 982nd Maintenance Squadron team Deep Purple was recognized recently during the 2008 Chief of Staff Team Excellence Award ceremony in Washington, D.C., at the Air Force Association's Air & Space Conference and Technology Expo.

The squadron was one of five Air Force organizations to claim the top prize from Air Force Chief of Staff Gen. Norton A. Schwartz.

Mitch Weatherly, flight chief for the squadron's trainer development flight, Randall Campbell, a sheet metal technician, and engineer Carl Cummings represented the team at the annual competition. Deep Purple's presentation highlighted the Fuse Deposition Modeling machine and a 3D scanner that enables the FDM to produce near-perfect models used for training aids.

"We highlighted several different projects that were huge impacts," Mr. Weatherly said, explaining how they've created trainers using the FDM and 3D scanner for MQ-1 Predator parts and a mock Minuteman III trainer for the nuclear munitions course here.

"Before, they didn't have that training. But, through the use of this technology, we've been able to build trainers faster and cheaper and build trainers that weren't previously available or too costly."

The FDM is able to take a computer drawing of a training device - or anything for that matter - and create a plastic replica at a fraction of the cost of purchasing the actual item.

For example, the cost of purchasing an actual KC-135 brake stack would be about $33,000. By using the FDM and scanner, the trainer development flight was able to make a replica at a cost of $1,778.66, a cost avoidance of $31,500 each.

During the competition, 20 teams provided 15-minute presentations for team performance and best practices within the Air Force to general officers and senior executive service officials. Following the presentations, members of the panel were allowed a 10-minute question and answer session.

According to a release by Air Education and Training Command Vice Commander Maj. Gen. Mark A. Walsh III, "The team boldly took the lead within 2nd Air Force by implementing (FDM) rapid prototyping and 3D scanning technology capabilities able to meet all training requirements on a global level. The Deep Purple team rapidly responded to numerous multi-diversified global training missions with a staggering $1.7 million Global War on Terrorism impact, along with a $3.7 million return on investment."

Put simply, the training development flight is having a direct impact on Sheppard's training mission, as well as Air Force, sister service and inter-agency customers that enhances the way business is conducted. That, Mr. Weatherly said, is why he chose the name Deep Purple.

"The reason I named the team Deep Purple was there was a diverse group of individuals that came together for a common purpose and achieve a goal," he said. "If you look at it, we've got the Air Force, total force, joint force and inter-agencies (as customers)."

Mr. Cummings said the FDM and 3D scanner enhanced the flight's ability to create accurate depictions of any training device.

"Our primary mission is to build hands-on trainers that are electrical and mechanical in nature," he said. "Students can put their hands on to assemble and disassemble these trainers.

He said the FDM and scanner gives the flight the ability to reverse engineer items that are out in the field, such as explosive ordnance devices.

"We are able to duplicate with the scanner what would require us to pull the parts and scan," he said.

Mr. Weatherly said the award was a total team victory, not just recognition for the three men who attended the conference.

"We will never get away from skilled technicians," he said. "A machine will never be able to take that away. The FDM and scanner is a means to an end.

"These guys have done a really good job. I have nothing to complain about."

Reaching this pinnacle doesn't mean it's time for the personnel at the trainer development flight to kick back and enjoy the riches of recognition. They are pushing forward to share the technology with other trainer development flights in the Air Force, as well as similar units in sister services.

"We've been on the trail trying to share this technology," he said. "Here's a technology you can use to do the same process."

The flight is hoping to get an FDM in the future that will create metal replicas instead of plastic, Mr. Weatherly said, furthering the realism of the training process.