In the aerospace and military sectors, legacy systems are often essential to maintaining operational readiness and national security. However, as technology evolves, these critical systems face an increasingly significant challenge: material obsolescence. Components that once powered communication satellites, radar systems, or military weapons platforms are aging, breaking down, or becoming impossible to source. These systems are often too important to discard, so organizations must grapple with the complex task of keeping them operational.
In this blog, we’ll explore some of the hidden challenges posed by material obsolescence in military systems, the innovative solutions emerging to address these difficulties, and how companies can navigate this evolving landscape.
The Hidden Challenges
1. Technical Complexity & Lack of Documentation
One of the first obstacles encountered when managing legacy systems is the lack of up-to-date design and change documentation. Older systems, particularly those designed before the advent of modern computer-aided design (CAD) tools, often come with files stored on outdated media or, in some cases, on paper. This makes it nearly impossible for engineers to easily upgrade or repair parts. The situation becomes even more complex when systems are classified and documentation is incomplete or restricted, making it difficult to reverse-engineer parts or understand the original design intent.
2. Supply Chain Disruptions
When components are no longer manufactured, sourcing replacement parts becomes a complex and costly exercise. For many legacy systems, these parts were produced by niche suppliers that may no longer exist or have scaled down their operations. The result is a fragile supply chain that is prone to delays and price hikes. Sourcing these parts might involve months or even years of searching, often through brokers, which increases the risk of counterfeit or subpar components.
3. Regulatory Challenges
Aerospace and military systems are heavily regulated to ensure compliance with safety, security, and performance standards. Many of these systems fall under regulations like ITAR (International Traffic in Arms Regulations), Cybersecurity Maturity Model Certification (CMMC) requirements, or export control laws, all complicate the sourcing of obsolete parts. Navigating these complex legal frameworks becomes even more difficult when sourcing components from foreign suppliers, especially when geopolitical dynamics shift unpredictably.
4. Cost of Requalification
When it is possible to replace or remanufacture obsolete parts, the next hurdle is often the cost of requalification. Many replacement parts must undergo rigorous testing and re-certification to ensure they meet current safety and performance standards. Re-qualification is a time-consuming and expensive process, and the older the system, the higher the cost and time involved in ensuring that new components can perform just as well as their predecessors.
5. Unexpected Lead Times, Tariffs & Shipping Costs
Sourcing obsolete parts often involves extended lead times, sometimes stretching to several months or even years. This is compounded by the added costs of international shipping, particularly when parts must be sourced from overseas brokers, which may also incur a tariff. The risk of counterfeit or substandard parts adds further layers of expense, as the parts will need to be thoroughly tested and validated before use.
6. Loss of Knowledge & Workforce
As the workforce ages, the institutional knowledge of legacy systems fades. Engineers who once worked intimately with older technologies are retiring, and finding new employees with the same skill set can be difficult. This knowledge gap can cause delays in maintenance and system re-engineering efforts, further complicating the problem.
7. Inventory Holding Costs
Maintaining inventory of obsolete parts can be costly. Not only does it require storage space, but over time, parts may degrade, become unusable, or expire. This increases warehousing costs and the likelihood that parts will eventually need to be disposed of, further compounding the cost of obsolescence.
Risks in Legacy Aerospace and Military Systems
1. Counterfeit Parts
As the pool of available components shrinks, the risk of counterfeit parts increases. Counterfeit components can jeopardize mission-critical systems and are often difficult to detect. The risk escalates when sourcing parts from unreliable brokers or international suppliers.
2. Compliance Risks
Non-compliance with regulations like ITAR, AS9100D, and CMMC can result in severe consequences, including penalties, loss of contracts, or security breaches. Ensuring that legacy systems meet the required regulatory standards is crucial for maintaining operational integrity.
3. Quality Control Risks
Legacy systems often rely on highly specialized components, making it difficult to find exact replacements. Even when parts are available, they may not meet modern manufacturing standards, creating concerns about safety, reliability, and performance.
Solutions to Address Material Obsolescence
1. Deal with What You Have
When replacement parts aren’t available, sometimes the best solution is to continue using existing parts as long as they remain functional and “findable”.
Some original equipment manufacturers (OEMs) or suppliers may still be able to provide support for obsolete parts, either by offering remanufactured units or by keeping legacy support channels open. Negotiating a long-term agreement with these suppliers for part replenishment or continued production can help mitigate obsolescence.
If possible, purchasing and storing a stockpile of critical spare parts before they become obsolete can help address future material shortages. This requires some foresight and investment upfront but can be an effective way to keep equipment operational in the long term.
In some cases, secondary markets, such as surplus equipment dealers, can provide hard-to-find or discontinued parts. These parts may be from decommissioned systems, so sourcing from this market can be a cost-effective solution, though it may come with risks regarding the condition, validity, and warranty of the parts.
2. Revisions to Update Specific Parts
If only certain parts are causing issues, it may be possible to replace just those components without overhauling the entire system. This approach minimizes costs and avoids the need for extensive requalification.
Part substitution strategy involves identifying functionally similar components that are still in production, and making modifications to adapt them for use in the legacy system. This approach requires careful consideration of the compatibility, safety, and functionality of the new parts but can allow you to avoid the cost of a full system redesign.
3. Re-engineering to Current Standards
When a full overhaul is necessary, re-engineering legacy systems to meet current standards can provide a long-term solution. While this process is resource-intensive, it ensures that legacy systems remain viable and meet modern safety, performance, and cybersecurity standards.
Re-engineering obsolete modules can offer improved performance, efficiency, and compatibility with current industry standards. Over time, this approach can provide savings on maintenance and improve overall system reliability.
Conclusion
Material obsolescence presents a growing challenge for the aerospace and military industries, but it is not insurmountable. With innovative solutions like additive manufacturing, and strategic partnerships, organizations can continue to keep their legacy systems operational without compromising performance or safety. By understanding both the risks and opportunities of material obsolescence, companies can better prepare for the future and ensure the longevity of critical aerospace and military technologies.
Need help keeping your systems alive and operational? Talk to the team that solves problems before they become failures. Contact DIVaero today!