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MAC II

Supporting our Warfighters Around the World

  • Supporting warfighter readiness with a cost-effective, deployable system
  • Organization: D&D Machinery and Sales, Inc.
  • Used by the Air Force and Allied Forces to assemble air-delivered munitions around the globe

200,000 Square Feet of
Manufacturing Capabilities

A/E32K-9 Munitions Assembly Conveyor (MAC II)

Munitions Support Equipment for our warfighters

  • Compact and light weight design
  • Utilizing commercial parts (COTS)
  • Rapid assembly/disassembly
  • Fully palatized unit
  • 40+ years in manufacturing
  • 200k ft2 with 3, 4 and 5 axis CNC, lathes
  • Large Flexible Manufacturing Systems (FMS)
  • 24/7 “lights out” operations
  • MIG/TIG and Flux Core welding.
  • Acceptance and load testing

RAMS (OLD) VS MAC II (NEW)

Rapid Assembly Munitions System (RAMS):

  • Limited to 1000lb. bombs
  • Designed in the mid-70s
  • Heavy steel construction

MAC II

  • 2,000lb. JDAM bomb capacity
  • Designed in 2000 using COTS components
  • Lightweight aluminum throughout

Mission Context

Problem Statement

  • Legacy system too heavy with limited capacity
  • Unable to support 2,000 lb. JDAM requirements
  • Need for lightweight, rapid deployment, with fast assembly
  • Air Force Combat requirements:
    • Modular
    • Rapid setup/teardown
    • Increased bomb assembly efficiency
    • Safety – reduced manual lifting and handling of heavy bombs

Solution Overview

  • MAC II (A/E32K-9) was developed for new generation requirements
  • Compact, lightweight, fully palletized
  • Uses Commercial-Off-The-Shelf (COTS) components
  • Over 120 systems have been manufactured and deployed worldwide

Key Features

  • Rapid assembly/disassembly
  • Improved air lines and tool trays
  • Bomb hoist integration
  • Compatibility – wide range of munitions GBU/JDAM and general-purpose bombs
  • CAD-driven engineering with 3D printing and CMM precision
  • Air transportable on a C-130 or C-17

Operational Benefits

  • Agile Combat Employment (ACE)
  • Increased sortie generation rate
  • Reduced manpower requirements (35%-50%)
  • Improved safety; reduced fatigue and injury
  • Decreased setup from 4-6 hours to 1.5-2.5 hours
  • No tools needed for setup
  • Minimal downtime due to COTS parts

Performance Results

  • Successfully fielded globally
  • ISO 9001:2015 certified manufacturing
  • Climate tested: +125F to -25F @McKinley Climatic Laboratory
  • Proven @ Operation Inherent Resolve
  • Red Flag and ACE proven rapid deployment

Implementation & Integration

  • Integrated into Air Force munitions operations
  • Fully palletized = transportable & deployable worldwide
  • Compatible with numerous bomb applications
  • Interoperability with the UK, Australia, Germany, and other NATO allies

Acquisition & Cost

  • 100% in-house manufacturing = cost efficiency
  • COTS components reduce sustainment costs
  • Unit cost: $500,000 ROM
  • Contract type: firm fixed pricing