Project Background

EngineeringPeople partnered with the U.S. Army to reverse engineer the Forward Repair System (FRS), a critical mobile combat repair platform containing mechanical, electrical, pneumatic, and hydraulic systems.
The project required complete disassembly, measurement, documentation, modeling, and reassembly of the system to produce a manufacturing-ready Technical III data package within six months.

The project involved documenting approximately 20,000 individual parts while overcoming limited reference information, complex welded assemblies, and intricate hydraulic and electrical routing systems.

Services and Solutions

EngineeringPeople delivered the following key services and solutions:

01

Reverse Engineering

Disassembled and documented the complete Forward Repair System to create an accurate digital engineering baseline.

02

3D CAD Modeling

Developed over 3,000 precision 3D models representing mechanical, hydraulic, pneumatic, and electrical components throughout the platform.

03

Technical Drawing Development

Produced 650 detailed manufacturing-ready engineering drawings for Army use and future sustainment efforts.

04

Hydraulic & Pneumatic System Modeling

Mapped and modeled complex hydraulic and pneumatic routing paths to accurately capture system functionality and assembly relationships.

05

Supplier Validation

Established and validated suppliers for custom-made and modified components required to support manufacturing readiness.

06

Technical III Data Package Delivery

Delivered a complete Technical III data package providing the U.S. Army with manufacturing-ready documentation and precision engineering data.

Technical Challenges

Limited Reference Information

The existing platform included incomplete documentation, requiring EngineeringPeople to reconstruct accurate engineering data directly from the physical system.

Complex Welded Assemblies

Many welded areas blended into surrounding sheet metal structures, making accurate measurement and modeling especially challenging.

Multi-System Integration

The project required simultaneous documentation of mechanical, hydraulic, pneumatic, and electrical systems with highly detailed routing and assembly relationships.

Safe System Access

EngineeringPeople developed safe procedures to lift and access the Forward Repair System assembly in order to document hidden hydraulic lines and electrical cabling.

Approach

Complete System Disassembly

EngineeringPeople carefully disassembled the Forward Repair System to document each component, subsystem, and assembly relationship throughout the platform.

Precision Measurement & Modeling

The team measured and digitally recreated thousands of parts and assemblies using advanced CAD modeling and reverse engineering processes.

Integrated Technical Documentation

EngineeringPeople consolidated all engineering data into a complete Technical III package containing manufacturing-ready 3D models, detailed drawings, and validated component information.

Modernize & Sustain
Mission-Critical Systems

Whether you need reverse engineering, legacy system documentation, or manufacturing-ready technical data packages, EngineeringPeople helps defense and industrial organizations modernize complex equipment with precision and speed.

U.S. ARMY FORWARD REPAIR SYSTEM

650

3,000

20,000