Forging - Red Lion, PA Operations

GD-OTS, Red Lion, PA's mechanical press system uses induction heat as the vehicle for billet preparation prior to forging. Also the press is linked to a cold saw and a staging elevator capable of staging billets for uninterrupted production runs.

2500 TON AJAX Mechanical Press System

GD-OTS, Red Lion, PA completed a modernization program for this Erie Press System in July 1999. The system includes automated material handling that takes the piece apart from initial loading of raw bar stock through the sheer and forging process.

800 TON Hydraulic Extrude Press

Forging - Garland, TX Operations

Aluminum/Magnesium Forging

Precision Forgings-General Dynamics OTS produces precision forgings up to 300 square inch plan view and flashless forgings for valve bodies and side cylinder parts. These forgings require minimal final machining, have excellent grain flow and provide extremely high strength.

Conventional Closed Die Forgings-General Dynamics OTS produces conventional forgings up to 800 square inch plan view. Conventional forgings include, but are not limited to: landing gear components, structural components, aircraft wheels, actuating arms, bell cranks, transmission housings, window frames and ordnance parts such as fins and wings.

Forward and Backward Extrusion-General Dynamics OTS produces both backward and forward extrusions from small cans to large extruded pots up to 46 inches long and 22 inches in diameter with wall thicknesses from one half inch to three inches.

Hand Forge-General Dynamics OTS produces hand forgings up to 1,200 lbs.

Rolled Rings-General Dynamics OTS produces rolled rings up to six inches tall and 48 inches in diameter with wall thicknesses greater than one inch.

Equipment and Processes

Engineering and Testing -
Niceville, FL Operations

Rock Hill Testing Facility

Located in Florida, 20 miles from the GD-OTS, Niceville, FL engineering center, Rockhill Testing Facility is an 800 acre test site fully equipped for experimental testing of warheads, a complete environmental and mechanical shock/vibration analysis, a 250m and 500m flight ballistic rocket range and a detonation physics research facility. The facility is also equipped with a monorail sled track for fully-instrumented diagnostic dynamic testing.

Warhead Systems Engineering Services

GD-OTS, Niceville, FL provides engineering services to the U.S. Government, prime contractors and various international customers. Included in this engineering support function are: aircraft compatibility engineering, exterior ballistics, accuracy, vulnerability, lethality and other special modeling and analysis. GD-OTS, Niceville, FL is in the forefront of advanced warhead design and development to support near term and future systems. Examples of technologies currently being investigated are blast fragmenting penetrators, long standoff warheads and miniature munition concepts. These developmental programs should become the basis for improved and new weapons systems in the near future. This expanded Warhead Systems capability will support our existing and new defense customer for the foreseeable future.

Engineering and Testing -
Garland, TX Operations

General Dynamics Ordnance and Tactical Systems Engineering Department possesses a wide range of capabilities to suit your engineering needs. The Engineering Department controls all design and fabrication aspects and methods of manufacture related to our products.

Using the latest state-of-the-art software available today, including the DEFORM© metal forming simulation program, ProEngineer©, and CATIA©, the design capabilities of the GD-OTS Engineering Department are virtually unlimited. These software packages are used throughout every phase of each project, from the proposal to final design and fabrication.

Our Engineering Department designs and assists in the manufacture of all the associated tooling, fixturing, and gauging for each product using CAD/CAM and virtual manufacturing techniques. Data is downloaded to our modern CNC machines to ensure flawless dimensional characteristic conformance and repeatability within each and every product.

Engineering and Testing -
Orlando, FL Operations

Since our formation in 1978 General Dynamics Ordnance and Tactical System Orlando Operations (Orlando Operations), formerly Engineering Technology, Inc. (ETI), has been quietly bridging technological possibilities to mission capabilities through innovation, principles and discipline to make the world less dangerous. Orlando Operations is located in Orlando, Florida, with engineering, testing and production facilities situated in and around the Central Florida Research Park immediately adjacent to the Navy Training Systems Division, the Army PEO-STRI the University of Central Florida (UCF).  Orlando Operations has a history as a research and development contractor whose principal product has been the engineering, design, and construction of special-purpose sensors and mechanical,

electromechanical, electronic, and electro-optic devices.  Orlando Operations can assume responsibility for all phases of a program from concept to execution including engineering analysis, design, materials selection, equipment fabrication, experimental diagnostics, computer modeling and simulation, performance and reliability testing, full rate production and documentation.  Our technical staff comprises all of the skills necessary to conduct most advanced and engineering development programs.  The skills of the Orlando Operations engineering staff include mechanical and aerospace engineers, chemists, computer software engineers, electrical and electro-optic engineers, mathematicians, and physicists.

Orlando Operations has been providing scientific and technical services to the DoD since 1978.  Over our long history of continuous advanced technology research and development for the military, Orlando Operations has developed an excellent and well-earned reputation and current contracts with agencies representing all branches of the armed services.  Our prior contract experience encompasses applied research, systems engineering, prototype development, operational and environmental testing, production, foreign equipment exploitation, and in-service product improvement.

 Our program management and accounting systems are approved by the DoD.  Orlando Operations has all the facilities, capital equipment, and personnel required to complete a diverse and comprehensive scope of research and product development programs.

Composite Process - Red Lion, PA Operations

GD-OTS, Red Lion, PA provides engineering services for product design and development and is a major manufacturing house for products employing carbon fiber. Today, GD-OTS, Red Lion, PA is the longest established single user of carbon fiber prepeg materials and offers several unique capabilities to its customers. For example, in-house proprietary and patented techniques include manufacturing processes using a Radial Layup to create cylindrical structures capable of extraordinarily high compressive strengths and sheer load for a variety of applications and industries.

The in-house R&D laboratory and engineering staff performs custom product design, production process development and prototype production. The plant has the capability to manufacture its own tooling and gages and conduct metal and composite properties testing. In addition, services include finite element analysis, exterior and interior ballistics calculations, and the performance of model shop prototyping.

In House Composite Process

GD-OTS, Red Lion, PA completed a modernization program for this Erie Press System in July 1999. The system includes automated material handling that takes the piece apart from initial loading of raw bar stock through the sheer and forging process.

Metal Fabrication - Garland, TX Operations

Sheet Metal Parts

Custom Manufacturing - General Dynamics OTS supports its customers' needs for turnkey custom manufacturing by using its precision sheet metal capabilities, which include hydroforming, stretchforming, deep draw forming, a broad range of sheet metal equipment and in-house heat treatment facilities.

Aircraft Refurbishment and MRO Support-General Dynamics OTS possesses decades of in house aerospace experience with aircraft tooling, specifications, manufacturing and parts production. General Dynamics OTS specializes in supplying its aerospace and MRO customers with single custom-made replacement parts from "splashes" and samples from overhauled aircraft to full run production parts

Prototyping - General Dynamics OTS's full range of capabilities and expertise with sheet metal fabrications and components is especially versatile for rapidly producing prototype parts to support of tight customer delivery schedules and developing manufacturing process plans for production runs after prototype part development.

Aerospace Structural Components - General Dynamics OTS's capability for producing aircraft structural components bridges both our forging capabilities and sheet metal capabilities. Some of the more complex components produced by General Dynamics OTS include landing gear (net forgings that require little machining), wing terminal fittings, anti-thrust kick back components, fuselage stringers, structural window frames and inside and outside aircraft skins.

Special Processes

• Thermal

• Non-Destructive

• Metallurgy

• Full Service Engineering

Metallurgy - Garland, TX Operations

GD-OTS maintains a state-of-the-art metallurgical laboratory for material characterization, property inspection, and product quality enhancement. The laboratory supports all General Dynamics OTS manufacturing operations including forging, machining, welding, sheet metal fabrication, heat treatment, and other metalworking processes. The laboratory investigations mechanical, physical, chemical, and microstructural property changes in materials, parts or assemblies throughout the manufacturing process and product life cycle. General Dynamics OTS is capable of testing a wide variety of materials such as carbon or alloy steels, stainless steels, and aluminum, magnesium, titanium, and other alloys. The metallurgical laboratory is certified by Bell Helicopter and Cessna Aircraft.

Special Process

• 3 Tension Testing Machines

• 9 Hardness Testers

• Conductivity Measurement Equipment

• Spark System Spectrometer

• Metallographic Preparation Equipment

• Polishing and Etching Facility

• Stereographic Macroscope

• Optical Microscope with digital photography capability

Demilitarization Capabilities

From Bullets to Bombs We Provide a Full Service Program Management Capability

GD-OTS has five years of highly successful experience as a Prime Program Management Contractor for the U.S. Army Joint Munitions Command in its program to reduce and recycle stockpiled munitions. This 5-year project is one of the largest demilitarization contracts awarded in the U.S.

As one of the leading integrated life cycle managers of conventional armament products and services in the world today, we have the ability to focus our Systems Management capabilities to the safe and efficient demilitarization of a wide variety of surplus munition items.

Our demilitarization Program Management capabilities represent a comprehensive base of technology and experience in munitions life cycle management.

GD-OTS has extensive Systems Management capabilities in the development and use of new technologies to safely and efficiently recycle these surplus munitions into valuable commercial materials. These technologies include dismantling munitions, metals, and plastics recovery and resale, and recycling explosive materials for commercial reuse.

We have a highly experienced demilitarization team. The team includes experts in Program Management, engineering, environmental, health, safety and security, quality assurance, contracting, and systems management and integration.

As of May 2004, GD-OTS has managed the safe and successful demilitarization, and recycling of more than 40,000 tons of surplus munition items.