The REF must maintain a clear understanding of the operating environment to successfully provide rapid solutions. Therefore, REF military personnel, subject matter experts and engineers deploy to forward operating centers where they work hand-in-hand with Soldiers on the ground. REF deployed its first forward teams to Afghanistan in November 2002 and, since 2003, REF has consistently maintained a presence there. REF forward teams execute the following essential duties:

• Provide Commanders and Soldiers at all levels with the ability to address evolving threats and operational challenges
• Conduct unit liaison activities to maintain situational awareness of current plans and operations and serve as a link from the forward deployed commands to the REF team at Fort Belvoir
• Execute Expeditionary Lab capability to deliver immediate solutions to Soldier capability gaps
• Identify requirements and oversee solution delivery
• Manage the sustainment of REF systems, including repair parts and Field Service Representatives (FSRs)
• Act as contracting officers and government oversight for REF projects ensuring adherence to contracting requirements in theater
• Conduct supply transactions and property book accountability
• Execute Expeditionary Lab capability to deliver immediate solutions to Soldier capability gaps

Over the past twelve years, the locations and footprints of REF operating centers have expanded and contracted to meet requirements. At the peak of Operations Enduring Freedom and Iraqi Freedom, REF deployed forward teams to Afghanistan, Iraq and Kuwait. Today, REF maintains a small, forward operations presence in Afghanistan, Kuwait, and Iraq.

To facilitate adaptation and innovation at the point of need, the REF developed and deployed containerized “Expeditionary Labs” to Afghanistan and Kuwait. These labs are staffed by engineers from the U.S. Army Research, Development and Engineering Command and REF non-commissioned officers. Not only are the able to solve challenges at the point of need, the staff has reachback support to their entire Army problem-solving community. For more information, please see this handout

Each Ex Lab is equipped with:

• Global Communications Suite
• Computer Numerical Control (CNC) Machine
• 3D Printer
• Fabrication Tools
• Wire-fed Welder
• Plasma Cutter
• Microscopy
• Data Processing and Numerical Simulation
• Various Hand Tools
• Prepositioned Raw Material

M249 Bipod Link

Challenge: The standard issue M249 bipod attachment does not allow for horizontal movement, restricting the weapon capability.

Solution: In less than one week, the Lab developed and fit a new attachment that extends the range of M249 movement.

Operational Impact: The M249 can shoot in multiple directions without having to be manually repositioned, reducing the time it takes to engage a target.

Valve Stem Guard

Challenge: The exposed valve stems on military vehicles were easily torn off by obstacles, deflating the tire and preventing automatic re-inflation.

Solution: The Lab staff used 3D printed prototypes to design and fit metal guards specifically for these tires.

Operational Impact: More than 100 guards have been installed. No issues or broken valve stems have been reported on the trucks receiving the guards.

MK-48 Mounts

Challenge: Soldiers prefer to use the MK-48 on dismounted missions, but the REF-provided, Ironman backpacks are designed to feed ammo to the 240B and 240L machine guns.

Solution: Within 3 weeks, the Lab staff designed and fitted a 3D-prototyped bracket. They went on to produce and distribute 44 aluminum MK-48 adaptors.

Operational Impact: Soldiers can now use a variety of weapons with the Ironman backpacks. Additional mounts have been requested by units in the field.

5590 USB Power Supply

Challenge: Soldiers carry a variety of electronic devices that use USB cables for charging during missions, but it is difficult to find charging stations for these technologies in the field or at remote bases.

Solution: The Lab staff developed a converter that can be attached to the readily available 5590 battery.

Operational Impact: Any electronic device that uses a USB cable can be charged using the 5590 battery.

Handheld IED Detector Light Mounts

Challenge: Soldiers using handheld IED detectors at night could not illuminate the ground beneath the sensor without interfering with the systems.

Solution: The Lab staff used the 3D printer to prototype several iterations of tactical light mounts.

Operational Impact: Soldiers can now attach 3 lights to the detectors. The demand outpaced the Ex Labs’ production capacity, and REF partnered with the Dept. of Energy to print and deliver approximately 500 mounts.

Any Soldier can submit a 10-liner to request solutions and meet operational challenges. We are also seeking Soldier assessments, feedback and ideas.

Soldiers looking to get in touch with a REF Forward team should contact REF Operations through this form or by unsecured phone at 703-704-0937. The Operations Center can also address questions regarding the repair, sustainment or disposition of a piece of REF-issued, nonstandard equipment.