The U.S. Air Force hired MERC to reverse engineer a drive system for the 20mm ammunition loader for use on the F-15, F-16 and the new F-22 fighter.

The Air Force desired to use a load head from an older system on a new ammunition loader trailer; however, the gear drive ratios were incompatible.

MERC determined the appropriate gear ratio and established an envelope for the load head input gear that would fit all three aircraft.

The gears, shafts and housing from the input gear assembly were CAD-designed using solid modeling.

The models were used to directly generate prototype parts from CNC equipment. MERC assembled the components and performed initial operational and durability testing.

The reverse-engineered system loaded ammunition smoothly in all aircraft and the design proved to be an effective and durable solution.

Learn more about MERC’s reverse engineering capabilities.