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CAPABILITIES

DESIGN ENGINEERING

Flyer’s design capabilities have roots in commercial vehicle development, coupled with extensive military vehicle experience in development, manufacturing and operational settings. Flyer’s engineering staff has backgrounds in military systems engineering, aerospace, automotive commercial and off-road race car development, vehicle test, and specialized vehicle components. Working in a team-oriented environment, we leverage our broad experience to create a uniquely synergistic design approach. The success of this design team is demonstrated in creative approaches to design challenges.

 

Modeling & Simulation

M&S is used to rapidly evaluate the ability of vehicles to meet notional requirements and provide a “drive before build” capability. A principle goal of M&S is to support trade studies that are performed in development of next generation vehicles. Trade studies often focus on powertrain/drive line, chassis, steering, weapon systems, weight and center of gravity. Flyer Defense leverages previous M&S activities that are resident in our database to accelerate design efforts, saving both time and money before the build phase.

Finite Element Analysis

Finite Element Analysis (FEA) is conducted on the chassis and all critical components to ensure acceptability to peak loadings and fatigue cycles.

ADAMS

Comprehensive Automated Dynamic Analysis of Mechanical Systems (ADAMS) is conducted at both a system and a vehicle level to validate both steady state and dynamic vehicle responses on numerous events and vehicle configurations.

Safety Margin Analysis

Matlab and dedicated in-house software is used to analyze complete system events and resultant peak loads and associated fatigue cycles to ensure safety margins are always present. The high fidelity of all analysis conducted and physical correlation to physical testing is considered a critical success factor. Virtual analysis enables a plethora of “what if” analysis conducted under strict “Design of Experiments” guidelines and criteria.

2 Base vehicle chassis measuring 60 inches and 72 inches wide
Flyer 60 ALSV Fulfilling ITV Requirement
Flyer 60 ALSV Fulfilling ITV Requirement VIEW CASE STUDY Flyer 60 ALSV Fulfilling ITV Requirement
In August 2013, U.S. SOCOM awarded General Dynamics Ordnance and Tactical Systems a contract under the GMV 1.1 Program for 1,297 vehicles based on the Flyer 72 ALSV design.

SYSTEMS ENGINEERING

Flyer Defense possesses expertise and experience in the total integration of commercially available off the shelf major systems and its own developed components with purpose designed military vehicle chassis, body and armament/weapon station structures and C4I systems.

Flyer Defense has developed and introduced many unique and robust solutions not readily available or to a level of technical readiness by any other company producing vehicles suitable for demanding military operations.

COTS

Wherever possible, the Flyer Family makes use of Commercial Off the Shelf (COTS) parts and maintains a high degree of commonality across the two base chassis.

Weapons Integration

Multiple flexible weapons stations allow the mounting of a variety of General Purpose and Heavy Machine Guns, Automatic Grenade Launchers, Chain Guns and even Anti-Tank Missiles. 

1,297 Number of GMV 1.1 vehicles initially procured by SOCOM

MANUFACTURING

Flyer Defense operates dedicated low volume manufacturing and assembly facilities in Inglewood and Gardena, California. Both facilities benefit from their proximity to Los Angeles International Airport (LAX) and a robust vendor and supplier base. These vendors complement all aspects of the manufacture and build operation to provide seamless production.

Lean manufacturing and flexible production lines is the cornerstone of the Flyer Defense build strategy. Our setup is extremely robust to support modest vehicle volumes without the necessity for additional production lines and associated tooling. We are partnered with General Dynamics Ordnance and Tactical Systems (GDOTS) to provide the higher volume manufacturing associated with the U.S. Special Operations Command (SOCOM) General Mobility Vehicle 1.1 Program, which is occurring at the GDOTS facility in Anniston, Alabama.

Our own production capacity is purposely based on manual labor, with the flexibility to add a more mechanized arrangement with dedicated welding robots. This is well understood and accounted for and further strengthens the total program build plan and capability.

Flyer implements the use of critical automotive tools and practices including Advanced Production Quality Plan (APQP) and Production Part Approval Process (PPAP).

Lean Manufacturing
GD-OTS Mass Production
295 Additional Flyer vehicles procured by U.S. Army to meet mobility needs

TESTING

Initial total Vehicle and System Testing and Validation are conducted within Flyer Defense. Vehicles are tested in both static and dynamic events to prove out the robust performance of the power train, suspension, body structure, steering, braking, electrical and electronics, human factors (i.e. ergonomics) etc., prior to any outside vendor participation.

Testing environments include internal test rigs and jigs and on/off road evaluations under a variety of terrain and temperature gradients. Flyer Defense uses recognized test facilities such as Aberdeen Test Center (ATC) and Nevada Automotive Test Center (NATC) to support shakedown testing, durability testing, accelerated life cycle testing, stability testing, weapons firing, model validation, etc.

Flyer vehicles have been through numerous testing events both within the United States and abroad including performance, ride quality and reliability, availability, maintainability, and durability (RAM-D).

Full Systems Test
3rd Party Certification

INTEGRATED LOGISTICS SUPPORT (ILS)

Flyer provides all necessary support to our domestic and international customers. This support includes operator and maintenance training, operator and maintenance manuals, spare parts and special tools required to support maintenance site operations, and on-call technical support.

Domestic
International

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