Next-Stage C4ISR Bandwidth: The AEHF Satellite Program

The USA’s new Advanced Extremely High Frequency (AEHF) satellites will support twice as many tactical networks as the current Milstar II satellites, while providing 10-12 times the bandwidth capacity and 6 times the data rate transfer speed. With the cancellation of the higher-capacity TSAT program, AEHF will form the secure, hardened backbone of the Pentagon’s future Military Satellite Communications (MILSATCOM) architecture, with a mission set that includes nuclear command and control. Its companion Family of Advanced Beyond-line-of-sight Terminals (FAB-T) program will give the US military more modern, higher-bandwidth receiving capabilities, and add more flexibility on the front lines. The program has international components, and partners currently include Britain, Canada, and the Netherlands.

This article offers a look at the AEHF system’s rationale and capabilities, while offering insight into some of the program’s problems, and an updated timeline covering over $5 billion worth of contracts since the program’s inception.

• The AEHF Program [updated]
• The AEHF Satellites
• The AEHF Satellites: Contracts & Key Events, full history [updated]
• FAB-T Terminals and Ground Control
• FAB-T & Ground Control: Contracts and Key Events, full history
• Additional Readings

The AEHF Program

Advanced EHF satellites will provide at least 10 times greater total capacity and offer channel data rates 6 times higher than current Milstar II communications satellites, while providing 24-hour low, medium, and high data rate satellite connectivity from 65 N to 65 S latitude worldwide.

The AEHF program began in April 1999, and development started in September 2001. The AEHF partnership program currently includes Britain, Canada, and the Netherlands. The original intent was to launch the first satellite in late 2007, and the production decision was made in June 2004. NSA delays in providing key cryptographic requirements ended up being very expensive, and other difficulties have also pushed the program back. First launch didn’t take place until August 2010 (Q4 FY10).

The program’s 2001 baseline cost of $6.15 billion for 5 satellites has also slipped, and changed, over the years. As of 2009, the program total was $10.3 billion for 4 satellites, a per-unit cost increase of 109.3%. R&D costs had jumped 51.7%, from $4.75 billion – $7.2 billion, but procurement costs skyrocketed even faster. From an initial estimate of $1.4 billion for 5 satellites (mean avg. $281 million per), procurement costs rose to $3.1 billion for 4 (mean avg. $775 million per). In the April 2010 SAR, the program had settled in at total R&D and production estimates of $12.45 billion for 6 satellites. On a per-satellite basis, that’s still a 67.2% jump from the 2001 baseline.

Like a number of current US satellite development programs, the AEHF program has been cited for cost overruns and schedule slips, owing partly to the US National Security Agency’s failure to furnish key cryptography requirements and specifications, and partly to mechanical and construction difficulties.

Along the way, the AEHF program’s size has yo-yoed. In December 2002, optional satellites 4 and 5 were deleted from the program, with the intention of making AEHF only an interim bridge to the larger Transformational Satellite Network (T-SAT) program. As TSAT faltered, however, the bridge became the destination, and the number of AEHF satellites rose to 6.

The first indication of shifts in the program came when the Pentagon’s April 2008 Selected Acquisition Reports confirmed that the program had expanded to add AEHF-4. The TSAT successor program was restructured, but in June 2009, Secretary of Defense Gates finally lowered the boom and confirmed that the Pentagon intended to kill TSAT, leaving AEHF satellites as the military’s main future guarantors of secure, hardened bandwidth. Efforts to look at the overall gap created by TSAT’s removal, determine priorities among wideband (WGS), hardened (AEHF), or other bandwidth options, and figure out how that gap might be covered, led to the restoration of AEHF-5, and the addition of a 6th satellite.

AEHF Space Vehicle-1 (SV-1) launched in August 2010, almost 3 years later than originally planned, but slightly earlier than some 2010 reports had expected. It encountered serious propulsion problems, which left it well short of its operational orbit, but ground control found some timely workarounds the eventually got the satellite to its orbital plane. The flip side is that instead of conducting on-orbit testing in August 2010, the USAF had to wait until November 2011.

AEHF SV-2 and SV-3 are ready, but AEHF SV-1’s technical failure and delayed on-orbit tests left them on hold. SV-2 was slated for launch in May 2011, but was eventually launched on May 4/12 2012.

SV-3 has missed its January 2012 window; the question now is by how much. As of Feb. 2012 the Air Force stated that it would launch in Q3 FY13 at the earliest. AEHF SV-4 is expected to launch in Q3 FY17, with SV-5 following in 2018 and SV-6 in 2020.

USAF budgets as of the FY 2013 President Budget are displayed below. They do not include the US Army’s small participation, contribbutions from international partners, or RDT&E funding beyond FY13:

• FY 2010: Funds the launch of AEHF SV-1 in FY 2010; continues assembly, integration and testing of AEHF 2 & 3, and builds the remaining majority of AEHF SV-4.

• FY 2011: Funds only on-orbit testing of AEHF SV-1, AEHF SV-2 launch, ongoing AEHF 3 & 4 work, and some advance parts for AEHF-5.

• FY 2012: Includes SV-1 on-orbit tests; SV-2 launch and on-orbit support, Mission Control System development; beginning of AEHF 5-6 block buy.

Satellites 5 & 6 are expected to cost almost double the average for SV 1-3, owing to a production line that was interrupted because of late decisions to add satellites; future budgets must also expect spikes to deal with those purchases.

The AEHF Satellites

As envisioned by the Pentagon at the moment, the fully operational Advanced EHF constellation will consist of 6 crosslinked satellites providing coverage of the Earth from 65 degrees north latitude to 65 degrees south. The confirmed program change to add a 4th satellite in April 2008 reflected slipping schedules and rising costs for the T-SAT program, which was finally canceled. In April 2010, the number was raised to 6.

Each Advanced EHF satellite employs more than 50 communications channels via multiple, simultaneous downlinks. To accomplish their goal of 10x the total capacity and 6x the data capacity of existing Milstar II satellites, Advanced EHF adds new higher data rate modes and will provide:

• 8 full time spot beam antennas @ 75 bps to 8.192 million bits of data per second (Mbps) to future Advanced EHF Army terminals.

• 24 time-shared spot beam antennas @ 75 bps to 2.048 Mbps data rate

• 2 inter-satellite crosslink antennas per satellite (10 Mbps) for global communications, eliminating the need to route messages via terrestrial systems and so eliminating some of the latency associated with satellite links.

• Up to 160 cellular coverages (75 bps to 8.192 Mbps)

• X-band frequency data rate capable, in addition to the Milstar low data rate and medium data rate modes that ensure backward compatibility.

Bandwidth is already a significant constraint in theater, and these higher data rates will allow more transmission of tactical military communications such as real-time video, battlefield maps, and targeting data into remote areas.

The AEHF Satellites: Contracts & Key Events

The Pentagon DefenseLINK summaries of awarded AEHF contracts are unusually informative, and provide a commendable level of insight into the program and its challenges. Note, especially, the effects of key delays from NSA re: cryptography. We’ve also broken out the AEHF’s FAB-T terminals that will connect the military to the AEHF network and other satellites. Though the two items are intertwined on many levels, and some cryptography-related contracts may mention neither but apply to both, separation of these contracts adds more clarity.

The Pentagon’s April 2008 Acquisitions Report placed a 4th AEHF satellite in the program, which had grown to 6 as of the most recent December 2010 SAR. Lockheed Martin is currently under contract for 4 satellites as of December 2011, but contracts covering long-lead items for a 5th and 6th satellite have begun.

Unless otherwise specified, the Headquarters Space and Missile Systems Center in Los Angeles, CA has issued the following requisitions under contract #F04701-02-C-0002:

Dec 5/11: Lockheed Martin Space Systems Corp. in Sunnyvale, CA receives a $167.2 million firm-fixed-price and cost-plus-incentive-fee contract modification, to buy more AEHF SV-5 & SV-6 long lead time materials. This comes on top of the $60 million Nov 16/11 announcement, and includes the basic long-lead parts for Lockheed Martin’s electronic boxes and core structure, and for Northrop Grumman’s payload. These parts have a 24-week (about 6 month) lead time, and will support the coming SV 5/6 production contract.

Work will be performed in Sunnyvale, CA (F04701-02-C-0002, PO 0528).

Dec 2/11: Lockheed Martin Space Systems Corp. in Sunnyvale, CA receives a $312.2 million cost-plus-incentive-fee contract modification for AEHF satellite program engineering support from Dec 1/11 to Dec 31/14.

Work will be performed at Redondo Beach, CA, and could include “on-orbit anomaly resolution and investigation” (vid. AEHF-1’s tribulations), flight and payload software sustainment after on-orbit tests are done, Networked AEHF System Tested tool sustainment, mission control familiarization, and development test. They’ll also provide hardware, software, training and logistics support, technical order maintenance, system security and information assurance engineering, support for AEHF and Milstar combined constellation integration transition and test activities, coordination with the Milstar O&M contractor, satellite database updates for Milstar and AEHF, and on-site technical support for satellite operations at Schriever AFB, CO, and Vandenberg AFB, CA. The USAF Space and Missile Systems Center’s Military Satellite Communications Systems Directorate in Los Angeles, CA manages the contract (F04701-02-C-0002, PO 0454).

Nov 16/11: Lockheed Martin Space Systems in Sunnyvale, CA received a $60 million firm-fixed-price and cost-plus-award-fee contract modification for AEHF SV-5 & SV-6 long lead time materials. The USAF Space and Missile Systems Center’s Military Satellite Communications Systems Directorate in El Segundo, CA manages the contract (F04701-02-C-002, PO 0525).

Nov 3/11: The USAF announces that AEHF SV-1 has completed initial activation of its communications payload, and has begun on-orbit testing. This included successful deployment of the payload wings, the Gimbal Dish antennas, and the Advanced Anti-Jam Nulling antennas, as well as log-ons and data communications using communication terminals located at Schriever AFB, CO, and M.I.T/Lincoln Labs, MA.

A combined team of Air Force, Aerospace Corp., Lockheed Martin, and Northrop Grumman personnel have worked on activation, and SMC MILSATCOM Systems Director Dave Madden believes that by the end of November, they’ll have enough data to make a decision on whether or not to launch AEHF SV-2 in April 2012.

Oct 25/11: The USAF announces that AEHF-1 has finally reached its designated orbital slot, 14 months after launch. The process required approximately 500 thruster burns, but they still expect to get the required 14 years of mission life from the satellite, even though onboard fuel is directly correlated with mission life. Other US satellites have lasted longer than expected in orbit, so it’s hard to evaluate the USAF’s expectation without knowing the before/after confidence intervals, safety margins, etc. Time will tell.

The next step is a 4-month detailed test and checkout phase of all spacecraft systems, which is actually the most critical on-orbit phase. If the satellite’s other systems are performing as expected, the Space and Missile Systems Center plans to transfer satellite command authority to USAF Space Command’s 14th Air Force in early 2012. USAF.

Oct 4/11: The Space & Missile systems Center at Los Angeles AFB says that AEHF-1 is going to be a bit late to its orbital slot. It will arrive in late October instead of today, “while maintaining the safety of the vehicle and conserving on-board fuel.” Burning the Hall Current Thrusters to make up for the Liquid Apogee engine’s problems has a price, as fuel is the main determinant of satellite lifespan in orbit. The MILSATCOM Systems Directorate says that when they achieve the desired orbit, AEHF-1 will maintain the same expected capabilities they were estimating back in June.

Sept 30/11: Lockheed Martin Space Systems Corp. in Sunnyvale, CA received a $9.8 million cost plus award fee contract modification to extend AEHF sustaining engineering support by 2 more months, from Sept 30/11 through Nov 20/11. Support is provided for MilStar and AEHF satellite operations at Schriever Air Force Base, CO and Vandenberg Air Force Base, CA, and includes on-orbit anomaly resolution and investigation, flight and payload software sustainment, Networked AEHF System Tested Tool sustainment, support for mission control segment Increment 5 familiarization and development test, mission control segment Increments 4 and 5 software maintenance, and on-site technical support.

The USAF Missile Systems Center Military Satellite Communications Systems Directorate in El Segundo, CA manages the contract (F04701-02-C-0002, PO 0519).

June 14/11: Layoffs at Lockheed Martin Space Systems. This branch of the firm employs around 16,000 employees in 12 states, but intends to shed 1,200 employees by year-end, including a 25% cut in middle management to reduce impacts elsewhere. LMSS’ Sunnyvale, CA; Pennsylvania; and Denver, CO sites will be hardest hit, and the firm’s release says that it’s pushed in part by several of their major programs moving beyond the labor-intensive development phase.

Space Systems says it will offer “eligible” salaried employees an opportunity for a voluntary layoff, plus career transition support for all affected employees. Lockheed Martin.

June 13/11: Lockheed Martin Space Systems in Sunnyvale, CA receives a $17.7 million cost-plus-award-fee contract modification, extending AEHF’s capabilities insertion study. As Lockheed Martin’s engineers contemplate ways to improve future AEHF satellites and meet growing military bandwidth needs, they will be performing capability/requirements tradeoffs for systems, technology assessments, development of design alternatives, risk assessments, and cost and schedule analysis (F04701-02-C-0002, PO 0500).

May 9/11: Lockheed Martin Corp. in Sunnyvale, CA receives a $21.3 million cost-plus-award-fee contract modification to develop AEHF program software changes in 3 areas. Absent further specifics, the award has been placed in this section.

Work will be performed in Sunnyvale, CA, and King of Prussia, PA. At this point, $19 million has been committed by the USAF Space and Missiles Center, SMC/PKJ in El Segundo, CA (F04701-02-C-0002, P00483).

April 15/11: The Pentagon’s Selected Acquisitions Report ending Dec 30/10 includes the “significant cost changes” in AEHF program – both satellites and terminals. The satellite section reads:

“Program costs increased $1,065.1 million (+8.6 percent) from $12,448.9 million to $13,514.0 million, due primarily to a revised procurement estimate to fully fund the fifth and sixth satellites (+$1,620.7 million) and an extension of interim contract support due to the launch delay for the first satellite (+214.5 million). These increases are partially offset by an estimating decrease due to an acquisition strategy change from full funding to a block buy for the fifth and sixth satellites (-$798.5 million).”

April 7/11: The USAF’s Space and Missile systems Center provides an update on AEHF-1 progress, as they work to move it into an operational orbit after it fell short upon launch. Today, AEHF-1 crosses the 20,000 km/ 12,427 mile perigee mark.

SMC says orbit-raising is successfully continuing as planned. Phases 1 & 2 using hydrazine thruster phase are complete, and the satellite is now using its AEHF’s Hall Current Thruster electric propulsion system. The goal is to reach geosynchronous orbit in late summer 2011. If they do, it would cap as remarkable effort, and a very nice recovery for the joint government and contractor team. On the other hand, fuel reserves are the #1 determinant of how long a geosynchronous satellite can remain effective, and AEHF-1’s fuel reserves will be much lower than planned. See also Nov 16/10 entry for more details. USAF SMC (no URL).

March 22/11: AEHF-1 crosses the half-way mark to geosynchronous orbit, with its perigee climbing above 17,893 km/ 11,174 miles altitude. USAF SMC (no URL).

Dec 15/10: Lockheed Martin Space Systems Co. in Sunnyvale, CA received a $1.31 billion contract modification for SV4, the 4th AEHF satellite, SV4 unique systems engineering, a system level factory test, system database management functions, systems level support equipment, and program management. At this time, $1.236 billion has been obligated (FO4701-02-C-0002; PO0448).

See also Sept 10/09 entry, USAF release.

Dec 14/10: In response to questions about AEHF-1’s orbital problems, the USAF Space and Missile Systems Center says they’ve briefed senior Air Force leaders, who are considering initiating a Safety Investigation Board. They will also present their investigation briefing to selected Congressional Staff Members later in December 2010. Based on the current costs for AEHF-1/2/3, the unit cost per satellite is about $1.7 billion, and the USAF is reviewing its options concerning contractor financial responsibility and/or penalties.

Under current plans, AEHF-1 is looking at a 9-month delay, reaching its test/check-out orbit on Aug 11/11, instead of Nov 10/10.

Nov 16/10: AEHF-1 may have launched successfully, but a propulsion system problem prevented a series of 3 liquid apogee engine burns, so it didn’t reach its operational mission orbit. Los Angeles AFB discusses the new plan to fix this, which involves 4 major stages:

The 1st Parking Burns stage used 3 of the 6 reaction engine assemblies, or REAs, to quickly raise the perigee altitude to reduce drag and attitude disturbances. The 5 pound thrusters brought the orbit to a perigee altitude of 1,156 km and an inclination of 19.9 degrees on Sept 7/10. Apogee altitude remained at 50,000 km, per plan.

The 2nd stage was a series of 6 REA Apogee Burns, to more efficiently raise the perigee path to 4,712 km, and lower inclination to 15 degrees. It was completed on Sept 22/10.

The 3rd stage involves firing 2 high-efficiency hall current thrusters (HCTs), for as long as 12 hours around the apogee altitude. These burns will continue every orbit, centered on apogee, and this stage is planned to last between 7-9 months. It began on Oct 20/10, with a 9 hour burn during AEHF-1’s 100th apogee. Meanwhile, the satellite has managed to deploy its solar arrays, and pass operational readiness checkouts.

The 4th and final stage will require a near-continuous firing of the HCTs to adjust to the final mission orbit, lasting about 3 months. Los Angeles AFB.

Nov 9/10: Lockheed Martin Space Systems Co. in Sunnyvale, CA received a $49 million contract modification for AEHF sustainment engineering support from Oct 1/10 to Sept 30/11. At this point, $9 million has been committed by the AFSMC/MCSQ in El Segundo, CA (F04701-02-C-002; P00427).

Oct 28/10: Lockheed Martin announces the end of Intersegment System Testing (IST) for the 2nd AEHF satellite in Sunnyvale, CA, completing pre-launch verification for the new eXtended Data Rate (XDR) high-bandwidth service. XDR offers a 10-fold increase in system capacity, coverage and network connectivity, allowing applications such as real-time video, and voice and data conferencing. Completion of IST for AEHF-2 caps an extensive suite of interoperability tests with new XDR-capable user terminals, which demonstrating protected anti-jam communications at data rates up to 8 Mbps using agile satellite spot beams.

The 2nd AEHF satellite has completed all testing, and will be placed in storage in November 2010. The 3rd AEHF satellite is currently progressing through thermal vacuum environmental testing at the Lockheed Martin facility in Sunnyvale, CA.

Aug 16/10: Lockheed Martin Space Systems Co. in Sunnyvale, CA received a $16 million contract to study AEHF enhancement options, and all funds have already been committed. With the demise of AEHF’s T-SAT successor, AEHF enhancements become a critical opportunity for the bandwidth-constrained US military (F04701-02-C-0002, P00443).

Aug 14/10: The USAF’s 45th Space Wing launches AEHF-1 from Pad 41 in Cape Canaveral, FL, on board a United Launch Alliance Atlas V rocket. USAF | Dutch MvD | ULA | Lockheed Martin | Florida Today, incl. video | Spaceflight Now.

August 10/10: AEHF-1 is encapsulated into the Atlas V rocket. The launch has been delayed again, until Aug 14/10.

July 16/10: Los Angeles AFB announces that, the Lockheed-Martin/Air Force AEHF team has continued a long-standing tradition, and signed a piece of the flight thermal blanket for the AEHF-1 satellite in preparation for launch. The satellite was shipped on May 24/10, and is currently at Cape Canaveral Air Force Station, FL being readied for launch.

July 14/10: The USAF announces that:

“The Atlas V launch of the first Advanced Extremely High Frequency satellite from SLC-41 at the cape has been delayed 10 days from 30 July to 10 August. This delay was necessary to provide engineers more time to perform confidence testing on a launch vehicle component associated with releasing the fairing support structure. Processing on both the launch vehicle and satellite continues nominally to a new launch date of 10 August. This slip in the AEHF-1 launch is not expected to impact other launches in the manifest.”

See USAF | Lockheed Martin | United Launch Alliance | Florida Today, incl. video | Spaceflight Now.

July 8/10: Integral Systems, Inc. in Columbia, MD receives a $13.4 million contract modification, extending the contract for the command and control system-consolidated (CSS-C) program for a year (from Sept 30/11 – Sept 30/12), due to launch delays on AEHF Space Vehicles 1, 2 and 3. At this time, no money has been committed; this contract just authorizes the funds if needed (F04701-01-C-0012, P00170).

CCS-C has been an overall money-saver for the USAF, migrating tracking, telemetry, and command and control from mainframe systems to cheaper and more flexible commercial client/server computing options. The USAF says that CCS-C sustainment costs are just 25% of the previous Satellite Control Network Command and Control Segment. After a competitive system ‘fly off’, in March 2002 Integral Systems Inc. (ISI) of Columbia, Maryland was awarded the CCS-C development/sustainment contract. ISI/CCS-C employs approximately 130 people, and operates 2 software development laboratories in Maryland and Colorado.

May 25/10: Lockheed Martin delivers the 1st new AEHF secure broadband communications satellite (SV-1) to the USAF, for a planned July 30/10 liftoff.

As of this date, Lockheed martin says that SV-2 has completed Final Integrated System Test, and is now preparing for Intersegment testing. SV-3 has now completed acoustic testing. Lockheed Martin.

April 14/10: Lockheed Martin announces that it has completed all factory testing of the first AEHF satellite, which means it’s ready for delivery to Cape Canaveral Air Force Station, FL for a September 2010 liftoff aboard an Atlas V rocket.

The 2nd AEHF satellite (SV-2) is in the midst of its final performance test known as Final Integrated System Test which will verify all spacecraft interfaces, demonstrate full functionality and evaluate satellite performance. The 3rd AEHF satellite, SV-3, is gearing up for acoustic testing.

April 1/10: The Pentagon releases its April 2010 Selected Acquisitions Report, covering major program changes up to December 2009. AEHF makes the list, owing to procurement shifts in the wake of TSAT’s cancellation:

“Program costs increased $2,510.3 million (+25.3%) from $9,938.6 million to $12,448.9 million, due primarily to a quantity increase of two satellites from four to six satellites (+$2,623.7 million). This increase was partially offset by decreases due to an adjustment to the cost estimate (-$20.0 million), Congressional general reductions (-$19.2 million), a contractor to civilian personnel conversion (-$11.8 million), and the application of revised escalation indices (-$53.9 million).”

March 30/10: The US GAO audit office delivers its 8th annual “Defense Acquisitions: Assessments of Selected Weapon Programs report. With respect to the AEHF, it’s a bit behind the curve in listing only 4 satellites in the program for its figures, but it does acknowledge them in its commentary. Excerpts include:

“The AEHF program has overcome the technical problems that have delayed the first satellite’s launch by almost 2 years and increased the cost of the program. Defective satellite parts were replaced and the satellite successfully completed system-level environmental testing…. Three satellites have been added to the program in recent years…. The cost of the fourth satellite is significantly more than the estimated $952 million (then-year dollars) cost of the third satellite because there is an estimated 4-year break in production and some electronics components are no longer manufactured. Program officials do not anticipate significant technical challenges, but integrating, testing, and requalifying the new components will require time and money…. design specifications for the first three satellites will remain unchanged for satellites four through six, which will be clones except for obsolete parts. The program office estimates the cost of satellites five and six will be about $1.6 billion and $1.7 billion (then-year dollars), respectively, with estimated launch dates in 2018 and 2020.”

Dec 1/09: Lockheed Martin Space Systems in Sunnyvale, CA received a $39.5 million contract to provide sustainment for the AEHF satellite ground segment from Dec 1/09 to Sep 30/10 (F04701-02-C-0002, P00399).

Oct 7/09: Lockheed Martin Space Systems in Sunnyvale, CA received a $21.6 million contract for AEHF satellites that will perform a 50% design adequacy assessment for the mission control segment and continue preparation for the preliminary design review as well as study the impacts on strategic command requirements. At this time, $4 million has been obligated (F04701-02-C-0002, P00383).

Sept 17/09: No TSAT. What Now? During a media roundtable with USAF Space Command’s Space and Missile Systems Center Commander, Lt. Gen. Tom Sheridan, he explains the way forward in the absence of TSAT. AEHF-4 and WGS F5/F6 have been added, but that will not make up the gap in space-based bandwidth. Meanwhile, the need for high bandwidth anywhere is exploding, thanks to the skyrocketing number of UAVs and other surveillance and/or remotely-operated platforms.

Efforts are now underway to look at the overall gap created by TSAT’s removal, determine the military’s overall priorities among military wideband (WGS), hardened (AEHF), or other bandwidth options, and figure out how that gap might be covered a piece at a time. New solutions will be an option, and so will the possibility of adding new technologies to existing platforms like AEHF.

If this doesn’t sound like a firm plan, it’s because there isn’t one yet. The current foci involve figuring out customer priorities, and finding near-term funding that would retain a number of TSAT personnel and engineers. Success in retaining these people is expected to ensure that they can bring their experience with next-generation technologies to help generate new options, and then analyze alternatives.

Sept 14/09: Lockheed Martin Corp. in Sunnyvale, CA received a $6.1 million contract to develop training material for increment 7, train the trainer for subject matter experts at Fort Gordon, and train international partners for the Advanced Extremely High Frequency Satellite program. At this time, $324,048 has been committed by the SMC/PKA in El Segundo, CA (F04701-02-C0002, P00353).

Sept 10/09: Lockheed Martin Space Systems Company receives a $22 million contract for advance procurement of long-lead parts for AEHF Satellite Vehicle 4. At this time, $11 million has been committed (F04701-02-C-0002, P00379).

Sept 10/09: Lockheed Martin announces that AEHF-1 has entered final testing at the company’s Sunnyvale, CA facilities, following successful completion of all spacecraft environmental testing. The Lockheed Martin-led team is now executing the final integrated spacecraft and system test procedures necessary to prepare the vehicle for flight. Over a 75-day period, the satellite will go through a series of factory tests to verify all spacecraft interfaces, demonstrate full functionality and evaluate satellite performance.

AEHF-1 was originally scheduled for launch in 2007, but the current release sets the bar for delivery at early 2010, and launch at an unspecified time in 2010. The 2nd and 3rd AEHF satellites are also progressing through final integration and test activities, and are currently on track for launch in 2011 and 2012 respectively.

March 31/09: American GAO auditors look at the AEHF program, as part of their 7th annual “Defense Acquisitions: Assessments of Selected Weapon Programs” report:

“For the second straight year, technical problems with satellite components resulted in a delay of the first launch. This latest delay is almost 2 years. Further, the program office estimates that the fourth AEHF satellite could cost more than twice the third satellite because some components that are no longer manufactured will have to be replaced and production will have to be restarted after a 4-year gap….

During system-level environmental testing of the first satellite, the program office identified six components with workmanship or design problems. Five of these components will need to be removed from the spacecraft for repair, and one will need a software fix. Once all components are repaired and reinstalled, the spacecraft will undergo environmental testing a second time to assure all components are working properly. Continued problems with integration and testing have led to additional schedule delays. The launch of the first satellite has slipped almost two years – from November 2008 to as late as September 2010. The launch of the second satellite was delayed from August 2009 to around June 2011, and the third satellite is now planned for launch in 2012. Due to these delays, initial operational capability has slipped 3 years – from 2010 to 2013.”

Feb 27/09: Lockheed Martin Space Systems in Sunnyvale, CA receives for $175 million for “the congressionally mandated advance procurement of long-lead parts in FY08 and FY09 for the Advanced Extremely High Frequency Satellite Vehicle four.” At this time $104.5 million has been committed (F04701-02-C-0002, POO347).

Feb 27/09: Northrop Grumman delivers the payload module for AEHF-3. They are 22 days early, marking 3 consecutive early deliveries to the Lockheed Martin’s Sunnyvale, CA facilities (2007, 2008, 2009). Their payload module consists of the complete set of processing, routing and control hardware and software that handle the satellite’s communications, including critical features that protect against interception or jamming.

Lockheed Martin now will begin mating the payload module with its A2100 satellite bus and other space vehicle components, to be followed by environmental and acceptance testing of the completed satellite. NGC release.

Dec 30/08: Lockheed Martin Space Systems in Sunnyvale, CA received a $7.2 million modifications, authorizing Lockheed to perform 2 additional thermal vacuum (TVAC) cycles on the AEHF Space Vehicles 2. As the Dec 16/08 entry notes, AEHF-1 is already facing problems due to TVAC related anomalies.

The US Air Force Space and Missile Systems Center (SMC), Military Satellite Communications Systems Wing at El Segundo, CA manages this contract (F04701-02-C-002, P00343).

Dec 30/08: Lockheed Martin Space Systems in Sunnyvale, CA received a $9.9 million modification to provide feasibility studies. These studies will center on extending the AEHF system in the Military Satellite Communications Program, which appears to bode ill for the $20+ billion TSAT program that was supposed to surpass AEHF. At this time, all funds have been obligated.

The US Air Force Space and Missile Systems Center (SMC), Military Satellite Communications Systems Wing at El Segundo, CA manages this contract (F04701-02-C-002, P00340).

Dec 16/08: Lockheed Martin Space Systems Co. in Sunnyvale, CA receives a $252 million Change Order that will implement additional vehicle-level Thermal Vacuum (TVAC) testing for AEHF-1. The DefenseLINK release adds that:

“The first Advanced Extremely High Frequency (AEHF) satellite is undergoing a significant amount of rework on mission critical unit’s dues [sic] to anomalies.”

At this stage, anomalies are very bad news. Additional TVAC testing suggests that the problem affects the satellite’s ability to survive and operate in the vacuum and wildly varying temperatures that a space satellite must endure.

Nov 17/08: The latest Pentagon Selected Acquisitions Report finds the AEHF program on the announcements list again:

“Program costs increases $2,576.6 million from $5,645.3 million to $9,938.6 million (+35.0%) to reflect cost increases which have resulted in a critical Nunn-McCurdy unit cost breach currently undergoing certification review.”

This is slightly confusing, as the April 2008 announcement set costs at $7.36 billion – rising from $6.42 billion because they had added a 4th AEHF satellite to the program.

Sept 16/08: Northrop Grumman Corporation announces that they have integrated all electronic units for AEHF-3’s payload module. The equipment includes approximately 20 electronics units that offer a complete set of radio frequency, processing, routing and control hardware, plus approximately 500,000 lines of software code.

NGC is currently under contract to provide 3 communications payloads to AEHF prime contractor Lockheed Martin in Sunnyvale, CA, and has delivered the first 2 on or ahead of schedule. This integration with Lockheed Martin’s A2100 satellite bus leaves the firm on track to maintain that record.

July 18/06: A $119.2 million modification to a cost plus award fee, cost-plus fixed-fee, cost-plus incentive-fee, firm-fixed-price contract with Lockheed Martin Space Systems Corp. of Sunnyvale, CA (F04701-02-C-0002, P00315). The modification covers long-lead parts for the 4th AEHF Satellite, and is an unfinalized contract whose exact numbers will be adjusted later. At this time $59.6 million has been committed.

April 7/08: Cost increases for the AEHF satellite and FAB-T terminal programs land them both on the Pentagon’s latest Selected Acquisition Reports release. The total increase is about 14.5% for the program as a whole, but the biggest increase is easy to understand – they added a satellite:

”[AEHF] Program costs increased $940.5 million (+14.6 percent) from $6,421.5 million to $7,362.0 million, due primarily to a quantity increase of one satellite from three to four satellites (+$946.0 million). Congress appropriated advance procurement for Space Vehicle 4 (SV-4) in the fiscal 2008 Appropriations Act. The Department added SV-4 Full Procurement in fiscal 2010, with a launch capability targeted in fiscal 2014.”

Feb 28/08: Lockheed Martin announces successful acoustic testing of the first Advanced Extremely High Frequency (AEHF) military communications satellite at its Space Systems facilities in Sunnyvale, CA. This test is designed to duplicate the sound and vibration levels expected during launch into orbit.

Lockheed Martin Space Systems and payload supplier Northrop Grumman Space Technology can now proceed with thermal vacuum testing, which tests performance in the enormously wide temperature extremes found in space. AEHF-1 will be shipped to the Air Force in late 2008 in preparation for launch aboard an Atlas V launch vehicle.

Jan 16/08: Raytheon Network Centric Systems, Inc. of Marlborough, MA received a contract for $37.5 million. The firm will perform a Minuteman Minimum Essential Emergency Communications Network Program upgrade to support communications via AEHF satellite constellations. To give you an idea of just how serious that is, the Minuteman-III fleet is the USA’s set of land-based nuclear missiles. The upgrade will provide an improved terminal operator control function, add an AEHF and address other system improvement for the MMP. At this time $15.2 million has been obligated. The Electronic Systems Center, AFMC at Eglin Air Force Base, FL issued the contract (FA8726-08-C-0004).

June 26/07: Integral Systems, Inc. in Lanham, MD received a $5.8 million cost-plus-award-fee contract modification. It modifies the Command and Control System-Consolidated (CCS-C) effort to support the Wideband Gapfiller Satellite (WGS) Program Operations Readiness, add training, and incorporate changes to the system/Subsystem Specification (SSS) to clarify development requirements for the Advanced Extremely High Frequency (AEHF) satellite program.

The CCS-C program provides an upgraded capability to command and control the Air Force’s communication satellites, including the Defense Satellite Communication System, Milstar, Advanced Extremely High Frequency, and Wideband Gapfiller Satellites (N.B. now also called Wideband Global SATCOM, but this was the language of the US DefenseLINK release). At this time, $2 million has been obligated, and work will be complete in June 2010. The Headquarters Military Satellite Communications Systems Wing in Los Angeles Air Force Base, CA issued the contract (F04701-01-C-0012/P00118).

June 18/07: Lockheed Martin announces that it has successfully integrated the AEHF’s spacecraft propulsion core structure and the payload module. The core structure contains the integrated propulsion system as well as panels and other components that serve as the structural foundation of the satellite. The payload module consists of spacecraft electronics as well as the complete set of payload processing, routing and control hardware and software that perform the satellite’s communications function.

The successful integration allows the team of Lockheed Martin Space Systems in Sunnyvale, CA and payload supplier Northrop Grumman Space Technology in Redondo Beach, CA to begin system level environmental and acceptance testing in preparation for launch in mid-2008. Lockheed Martin release.

June 1/07: Raytheon Co in Marlborough, MA received a $27.1 million3 firm-fixed-price contract for production, test, and delivery of 9 Extremely High Frequency (EHF) Satellite Communications Follow-On Terminal Communication Groups P/N: G752718-2 and 17 ship Antenna Groups P/N: G674898-1 (seven Radar Reducing Cross Section and ten Non-RRCS variants). This contract includes an option which, if exercised, would bring the cumulative value of this contract to $38.3 million.

Work will be performed in Largo, FL (61.8%); Marlborough, MA (36.8%); and Saint Pete, FL (1.4%), and is expected to be complete by May 2009. This contract was not competitively procured; it was synopsized as a sole source procurement via the Space and Naval Warfare Systems Command E-commerce web site on July 5, 2006. The Space and Naval Warfare Systems Command, San Diego, CA issued the contract (N00039-07-C-0001).

Feb 28/07: Lockheed Martin Corp. in Littleton, CO received a $108 million firm-fixed-price contract to launch AEHF-1 using an Atlas V Launch Vehicle under the Evolved Expendable Launch Vehicle (EELV) program. At this time, total funds have been obligated and work will be complete February 2009. The Headquarters Space and Missile Systems Center at Los Angeles Air Force Base, CA issued the contract (FA8816-06-C0004).

Dec 28/06: Lockheed Martin Corp. Space Systems in Sunnyvale, CA received a $7.8 million cost-plus-award-fee contract modification for the use of a commercial payload processing facility to test, integrate, and fuel the Advanced Extremely High Frequency satellite in preparation for launch. This modification replaces the use of a government facility with a commercial facility that meets program requirements for floor space sufficient to support simultaneous mechanical and electrical launch processing operations. At this time, $1 million has been obligated. The Headquarters Military Satellite Communications Systems Wing at Los Angeles Air Force Base, CA issued the contract (F04701-02-C-0002/P00214).

Dec 22/06: Lockheed Martin announces that it has delivered the flight structure for the 3rd AEHF satellite ahead of schedule. The flight structure, which is based on the A2100 geosynchronous spacecraft, will now be sent to Lockheed’s Mississippi facility for integration with its propulsion subsystem.

Over the next several months, a team of engineers and technicians at Lockheed Martin’s Mississippi Space & Technology Center, an advanced propulsion, thermal, and metrology facility located at the John C. Stennis Space Center, will integrate the spacecraft’s propulsion subsystem, which is essential for maneuvering the satellite during transfer orbit to its final location as well as conducting on-orbit operations and repositioning maneuvers throughout its mission life. See Lockheed Martin release.

Oct 19/06: Lockheed Martin Space Systems Co. in Sunnyvale, CA received a $7.7 million cost-plus-award fee contract modification. This undefinitized contract action involves integration of the NSA-developed top secret key translation element into the AEHF system, and authorizes Lockheed Martin to start working the system design and test program changes required. The modification will develop, test and integrate the required hardware/software in to the AEHF mission control segment.

At this time, $4.5 million has been obligated. This work will be complete June 2019. The Headquarters Military Satellite Communications Systems Wing, Los Angeles Air Force Base, CA issued the contract (F04701-02-C-0002/P00212).

Oct 4/06: Lockheed Martin Space and Missiles in Sunnyvale, CA received a $7.6 million cost-plus-award fee contract modification for software and hardware changes to the Advanced Extremely High Frequency (AEHF) satellite system. The changes are necessary to develop and maintain backward compatibility with the predecessor Milstar communications satellite system, and are part of a series of modifications necessary to ensure this compatibility. The Headquarters Military Satellite Communications Systems Wing at Los Angeles Air Force Base, CA issued the contract (F04701-02-C-0002/A00013).

April 19/06: Lockheed martin engineers perform a successful modal survey for AEHF. It is designed to ensure that launch and other sources of vibrations such as reaction wheels, solar arrays and various deployable and steerable mechanisms will not affect the critical mission of the communications payload. The successful test was performed by a team of engineers at Lockheed Martin Space Systems, facilities in Sunnyvale, Calif. and included 292 accelerometers, 508 accelerometer channels and six shakers mounted to the structure and surrounding ground surface. Lockheed Martin release.

April 14/06: Lockheed Martin, Space Systems Co. in Sunnyvale, CA received a $454.9 million cost-plus fixed-fee, cost-plus award-fee contract modification for the implementation of the Advanced Extremely High Frequency (AEHF) Satellite Communication System Program re-plan, which started in late 2004. The re-plan was necessary due to delayed delivery of government-furnished information assurance products, added payload component testing, and replacement of critical parts that were disqualified for space flight. The effort includes development of emulators, additional testing associated with integrating multiple incremental deliveries, and additional months of non-recurring development. The resulting AEHF first launch date of April 2008 is consistent with the revised Acquisition Program Baseline approved in March 2005. This work will be complete May 2010 (F04701-02-C-0002/P00136)

Jan 12/06: Lockheed Martin Corp. Space Systems Co. in Sunnyvale, CA received a $491.2 million cost-plus-award-fee, cost-plus-fixed-fee, firm-fixed-price contract modification. This is a modification of the Advanced Extremely High Frequency (AEHF) satellite contract to add satellite vehicle #3 (SV3) as envisioned and permitted by a clause in the contract. This action includes the procurement of SV3, and introduces the option for Launch and Operations support.

The Launch and Operations Support option associated with this modification is planned to be exercised beginning in FY 2009 to support an FY 2010 launch, and the acquisition of SV3 will complete the AEHF program of record unless the T-SAT program is deferred or canceled (in which case AEHF SV4 & SV5 will be launched). Work on this contract, which takes the total amount of AEHF expenditures announced on DefenseLINK to $4.276 billion, is expected to be complete in May 2011 (F04701-02-C-0002, P00156).

March 7/05: Lockheed Martin Corp. in Sunnyvale, CA received a $78.2 million cost-plus award-fee, cost-plus fixed-fee, firm fixed-price contract modification to provide for the advance procurement of long-lead parts for AEHF Satellite Vehicles #3 (SV3) in FY05 (F04701-02-C-0002, P00102).

Dec 21/04: The U.S. Air Force announces that the AEHF program has suffered a 1-year schedule slip, and cost growth of about 20%. The first launch of the 3 planned satellites is now slated for April 2008 rather than 2007 [Source]. In its release, the USAF cites:

”...unavoidable delays and cost growth due to delayed delivery of information-assurance [signal-encryption] products, and the resulting delay of terminals required for satellite command and control…. replacement of critical electronic parts and added payload component testing….”

Aug 4/04: Lockheed Martin Corp. Space Systems in Sunnyvale, CA and Northrop Grumman Space Technology in Los Angeles, CA received a $32.55 million cost-plus award-fee contract modification for spare critical components to be used, if necessary, in factory by the contractor during assembly and test and of Advanced Extremely High Frequency (EHF) satellites. Originally, five AEHF satellites were to be built, which ensured that there would be enough spare parts to avoid delays during production because the first satellites could use parts from satellites being assembled later. For this reason, the original AEHF plan did not include production spares. In November 2002, two of the Advanced EHF satellites were cancelled and the third satellite was delayed one year, which meant there were no longer adequate numbers of spare critical parts to prevent production delays. Work will be complete by January 2009 (F04701-02-C-0002, P00083).

May 18/04: Lockheed Martin Corp Space Systems and Northrop Grumman Space Technology received a $149 million contract modification which incorporates within-scope changes resulting from Revision to the KI-54 Cryptographic Interface Control Document (ICD). The KI-54 ICD “black box” encryption device was modified by the NSA’s (National Security Agency) contractor, which meant the AEHF team was required to redesign the Host Accessory Logic Application Specific Integrated Circuit (HAL ASIC) in the AEHF communication payload. This effort was captured in Phase 1. In Phase 2, the AEHF contractor team will receive a four months program extension to identify and mitigate the risks and modifications to the whole satellite associated with this redesign. Locations of performance are: Lockheed Martin Corp. in Sunnyvale CA (51%) and Northrop Grumman in Los Angeles, CA (49%). This work will be complete in September 2008 (F04701-02-C-0002, P00061).

Dec 22/03: Lockheed Martin Missiles and Space in Santa Maria, CA received a $15 million cost-plus award-fee contract modification. This technical change will provide two different connection modes to allow MPE to communicate with Army and Air Force terminals and adapt to different terminal and network changes, as Option 5 of an analysis Study that defines Mission Planning Element (MPE) versus Terminal Functionality into the AEHF baseline. This work will be complete by September 2008 (F04701-02-C-0002, P00042).

Aug 8/03: Lockheed Martin Corp. in Sunnyvale, CA received a $78.5 million cost-plus award-fee, cost-plus fixed-fee, firm-fixed-price contract modification. It provides for an in-scope change to Incorporate KI-54 Interface Control Document (ICD) Revision F-Phase 2 impacts. The KI-54 ICD is a “black box” encryption device for military communications passing through AEHF. A two-phase approach was initiated to evaluate the KI-54 ICD Revision F changes. Phase I focused on the effort to redesign the HAL ASIC. Phase 2 focused on identifying and mitigating the AEHF system level impacts associated with the HAL ASIC redesign, as defined in Phase 1, such that the 4-month HAL ASIC PDR slip will not result in a launch delay. This work will be complete by September 2008 (F04701-02-C-0002, P00046).

July 23/03: Lockheed Martin Corp. Space Systems in Sunnyvale, CA and Northrop Grumman Space Technology in Los Angeles, CA received a $16 million contract modification for the following:

(1) Provide capability to assign any single uplink transmission security (TRANSEC) key to any beam;
(2) Provide capability to blank 2nd key contiguous bandwidth within any one permute group in multiples of wideband channels for every hope of the date frame. The blanking timing error shall be factory selectable and upload able from mission control segment (MCS);
(3) Allow extra high data rate users to acquire high gain earth coverage, reposition medium resolution coverage area (beam shared and full-time) and high-resolution coverage area beams without using super high gain earth coverage (SHGEC) uplink resources;
(4) Provide capability for all users to acquire and communicate in the same coverage requests, and the SHGEC which is only used for communications and time tracking terminals acquiring or communicating in any particular beam will do so using only one uplink TRANSEC key that is currently configured to that beam;
(5) Allow for permute group 0 group to support wideband channels.

This work will be complete in September 2008 (F04701-02-C-0002, P00043).

June 13/03: Lockheed Martin Corp. in Sunnyvale, CA received a $5.2 million contract modification to provide for in-scope changes to modify the Advanced Extremely High Frequency (AEHF) Payload. The technical change ensures backward compatibility with MILSTAR satellite operations. specifically, it will provide users the capability to fence the necessary payload resources to process Rapid Reconfiguration Order Wire (RROW) streams, and the capability to control the fenced RROW XC2 stream processing payload resources as any other fenced resource, including sub-fences and sub-sub-fences, via command and access control protocol. The change will impact multiple specification documents including the Mission Planning Element of the Mission Control Segment, the Configurable Onboard Router in the Digital Processing Subsystem and the payload software. This work will be completed in September 2008 (F04701-02-C-0002, P00031).

May 27/03: Lockheed Martin Missiles and Space in Sunnyvale, CA received a $10 million cost-plus-award-fee, cost-plus-fixed-fee, firm-fixed contract modification. This is an in-scope change to redesign the host accessory logic circuit (ASIC) in response to a specification upgrade for the KI-54 cryptographic device. This effort will ensure secure communication capability by providing an improvement to the host accessory ASIC within the AEHF digital processing subsystem. This work will be complete January 2004 (F04701-02-C-0002, P00034).

May 22/03: Lockheed Martin Space Systems Co. received a $9 million contract modification as an amendment to the existing system development and demonstration (SD&D) contract that was definitized April 15, 2001. The purpose of this amendment is to increase the contract value from $2.63 billion to $2.64 billion. This increase is the result of an engineering change proposal to implement a new AEHF System alternate key management plan (AKMP). The effort is within scope of the existing contract, and is necessitated by requirement/design changes that meet National Security Agency (NSA) security requirements that have been validated by Air Force Space Command. The system keys can’t be produced until the NSA approves the AKMP, and these changes must be implemented to avoid possible impact to the launch schedule. The locations of performance are Lockheed Martin Missiles and Space in Sunnyvale, CA, and TRW Inc. Space and Electronics Group in Redondo Beach, CA. This work will be complete June 2008 (F04701-02-C-0002, P00029).

May 22/03: Lockheed Martin Corp. in Sunnyvale, CA is being awarded a $498 million firm-fixed-price contract modification. This is an amendment to the existing letter contract for the Advanced Extremely High Frequency (AEHF) System Development and Demonstration (SD&D) phase. The purpose of this amendment is to increase the not-to-exceed from $2.698 billion to $3.196 billion, as a result of the FY 2002 appropriation act decrease of $70 million and the loss of $30 million in international partner funding. Also, the not-to-exceed increase includes effort necessitated by the recent revision of the National Security Agency’s KI-54 encryption Interface control document, revision D in the amount of $46 million. This action provides for satellites replacement and upgrade of the associated ground command and control segment, and the necessary sustainment. The period of performance for this effort will span approximately 10 years. Lockheed Martin Corp. will perform this effort at TRW Inc. Space and Electronics Group in Redondo Beach, Los Angeles, CA (46%), and Lockheed Martin Missiles and Space, Sunnyvale, CA (28%) and other locations (F04701-02-C-0002, P00007).

Nov 16/02: The Advanced Extremely High Frequency (AEHF) National Team, comprised of Lockheed Martin in Sunnyvale, CA, and TRW Inc. in Redondo Beach, CA, are being awarded a $2.698 billion (not-to-exceed) firm-fixed-price and cost-plus award fee contract for the System Development and Demonstration (SDD) phase of the AEHF satellite communication system program. This effort includes production of two satellites, plus replacement and upgrade of existing military satellite communication (MILSATCOM) ground command and control segment components to support AEHF and associated sustainment. Solicitation for this sole source contract began in October 2000, negotiations were completed November 2001, and work will be complete in December 2011. The contractors will perform this effort in Sunnyvale, CA (45%), and Redondo, CA (55%). The Space and Missile Systems Center at Los Angeles Air Force Base, CA issued the contract (F04701-02-C-0002).

FAB-T Terminals and Ground Control

FAB-T (Family of Advanced Beyond-line-of-sight Terminals) is designed to provide a family of software-defined radios that use a common open architecture to link to different satellites, and enable information exchange between ground, air and space platforms. It is envisioned as a common terminal for the next generation of High Data Satellite Communications using AEHF, Wideband Gapfiller, and other future satellite systems. Aircraft involved include bombers like the B-2 Spirit stealth bomber and B-52 Stratofortress, specialty platforms like the RC-135 Rivet Joint, E-4 NAOC, E-6 Mercury/TACAMO, et. al., and key UAV types like the RQ-4 Global Hawk and MQ-1/9 Predators.

The FAB-T family includes software-defined radios, antennas and associated user interface hardware that will provide a powerful system capable of hosting a multitude of transmission “waveforms” to accommodate data rates in excess of 300 megabits per second.

FAB-T Increment 1 will begin as a terminal for the AEHF and older Milstar satellite systems.

FAB-T Increment 2 will develop terminals to support Wideband Global SATCOM satellite operations on surveillance aircraft including key UAVs, with other platforms to follow.

Fortunately, FAB-T also is the first survivable Software Communications Architecture (SCA)-compliant communications system. Because its implementation will be software based, rather than hardware based, future upgrades that improve performance or extend the standard can be implemented without the time-consuming and expensive process of disassembling equipment and adding new electronics. These “future proofing” modifications can be made to any SCA-compliant radios if it is deemed necessary, even those outside the AEHF/FAB-T program.

FAB-T was initially a 6-year, $279 million system design and development contract, and it has now expanded to become an SDD/EMD and production program worth over $3.6 billion. Program activity is managed by Boeing’s Battle Management/Command, Control and Communications (BMC3) & Strategic Systems business segment in Anaheim, CA with key support from Boeing Satellite Systems of El Segundo, CA. Principal team members include:

• Boeing (Lead contractor, systems engineering and integration, system and terminal architecture, software development, test and evaluation, integrated logistics support and communications engineering)

• Harris Corporation’s Government Communications Systems division in Melbourne, FL (integration of terminal and antenna hardware)

• L-3 Communications’ Communications Systems West division in Salt Lake City, UT (development of the modem processor)

• Northrop Grumman’s Mission Systems (not specified, but acquired TRW whose Command, Control and Intelligence Division in Fairfax, VA was working on AEHF waveform management)

• Raytheon (related SMART-T terminals for USA, Canada and the Netherlands)

• Rockwell Collins’ Government Systems Division (not specified)

• ViaSat, Inc.’s Communications Systems Group in Carlsbad, CA (communications security module hardware and information security)

FAB-T & Ground Control: Contracts and Key Events

Sept 19/11: Raytheon announces that they have fielded the first AEHF Secure Mobile Anti-jam Reliable Tactical Terminal (SMART-T) satellite communications solution to the U.S. armed services, using Raytheon’s eXtended Data Rate (XDR) waveform hardware and software modification.

SMART-T is compatible with EHF and AEHF satellites, and AEHF increases the data rate by a factor of 4x. Through 2015, Raytheon will field 364 AEHF SMART-T terminals to the U.S. armed services, 19 systems to Canada and 7 to the Netherlands.

August 2011: Boeing successfully demonstrates high-data-rate transmissions between FAB-T and an AEHF test terminal, using the low probability of interception, low probability of detection extended data rate (XDR). XDR will be used for, among other things, nuclear command and control.

The testing covered XDR re-key, XDR text communications, dual FAB-T log-on with the AEHF payload, and interface with the AEHF Satellite Mission Control Subsystem. More than 50% of system integration tests are done, and system qualification testing is due to start in 2012. Note that Boeing’s Oct 3/11 release refers to Paul Geery as its FAB-T VP and program manager.

July 18/11: Boeing updates progress. The FAB-T EMD program has completed 90% of hardware qualification testing, 97% of all system software through-code and unit testing, and approximately 30% of systems integration and test. Boeing has conducted platform and payload integration testing through over-the-air low-data-rate tests and risk-reduction flight tests, and April 2011’s RC-135 Rivet Joint flight test of a Block 8 terminal was the 2nd in a series of airborne terminal tests, on the 1st operational program to be integrated.

Boeing is working toward the LRIP (low-rate initial production contract) for the Nuclear Command and Control Network Communications System, and completing qualification of the Block 8 third-generation hardware and high-data-rate waveform software. John Lunardi is currently Boeing’s FAB-T vice president and program director.

April 15/11: The Pentagon’s Selected Acquisitions Report ending Dec 30/10 includes the “significant cost changes” in AEHF program – both satellites and terminals. The FAB-T section reads:

“Program costs increased $630.9 million (+15.8 percent) from $3,981.9 million to $4,612.8 million, due primarily to complexities with software integration and challenges with hardware qualification (+$260.1 million), higher manufacturing costs due to loss of learning and production inefficiencies (+$258.9 million), and other increases due to the schedule stretch-out (+$134.7 million), partially offset by decreases in other support costs (-$32.7 million).”

April 6/11: Boeing in Huntington Beach, CA receives a $271.2 million cost-plus-award-fee contract modification. It covers “the new estimated cost completion” amount for FAB-T, and “provides increment funding aligned with Continuing Resolution authority.”

Work will be performed at Huntington Beach, CA, and Salt Lake City, UT. Hanscom AFB’s Electronic Systems Center, MA manages the contract (F19628-02-C-0048, P00219).

Jan 26/11: A successful demonstration of over-the-air, low-data-rate communication between an orbiting Milstar satellite and the a 3rd generation (Block 8) FAB-T terminal, passing voice and data communication using the FAB-T’s low-data-rate software and its newly developed large aircraft antenna.

The system in question demonstrates why this kind of backward compatibility matters: it’s a Nuclear Command and Control Network Communications System. The team of Boeing, L-3 Communications, Rockwell Collins and ViaSat, Inc. will conduct more terminal integration, software testing and flight testing activities before building this system.

Boeing’s System Integration and Testing Lab in Huntington Beach, CA includes 12 FAB-T systems with connections to 3 antennas, allowing simultaneous over-the-air operation. 2011 will feature in-depth FAB-T system integration tests, now that over 80% of the hardware qualification testing and nearly 65% of the FAB-T software qualification testing is complete. The program is scheduled to enter flight testing in Q1 FY 2013 (fall 2012), and exercise its low rate initial production option in Q3 FY 2013 (summer 2013). USAF.

Oct 6/10: Boeing in Wichita, KS received a $12.4 million contract modification for a future beyond line of sight (BLOS) communication capability on the B-52 heavy bomber, using AEHF-compatible BLOS terminals. At this time, $10 million has been committed by the ASC/WWVK at Wright Patterson AFB, OH (FA8107-05-C-0001; PO 0058).

This contract is part of the B-52 CONECT program.

Aug 3/10: Lockheed Martin announces that a joint company/USAF team has successfully transitioned the Milstar satellite constellation’s ground control system to the new AEHF Mission Control Segment (MCS). The AEHF MCS is now performing day-to-day operation of the USAs existing Milstar satellite constellation, leaving MCS ready to support deployment of AEHF-1 in August 2010. Lockheed Martin.

Jan 4/10: Boeing in Huntington Beach, CA received a $34.3 million contract to implement the following changes to the functionality available for the Family of Advanced Beyond Line-of-Sight Terminals Increment 1: Contractor Technical Requirements Document (CTRD) update version 9.2; Simple Key Loader 6.0 interface to data set manager (DSM) for DSM flash control station profiles; and implementation of auto broadcast features on the Extended Data Rate (XDR) capability. At this time, $500,000 has been obligated. The 653 ESW/PK at Hanscom Air Force Base, MA manages the contract (F19628-02-C-0048-P00180).

Oct 21/09: Rockwell Collins announces a 5-year, USD$ 52.3 million contract to provide the Canadian Forces with AEHF-compatible Single Channel Anti-jam Manportable (SCAMP XDR-IPV, Extended Data Rate International Partners Variant) terminals. The Foreign Military Sale contract will be executed through the U.S. Army’s Communications-Electronics Command Group (CECOM).

Rockwell Collins’ SCAMP terminals provide worldwide secure, jam-resistant, covert, voice and data communications. They offer communication for a wide variety of applications and users. The terminals feature Extended Data Rate (EDR) capability that delivers data rates comparable to high quality, Digital Subscriber Line (DSL) modems.

Oct 14/09: Boeing Launch Services of Huntington Beach, CA received a $21.8 million contract modification to provide engineering development models for the Family of Advanced Beyond-Line-of-Sight Terminals (FAB-T) to allow for operational testing with production representative terminals. FAB-T terminals will connect soldiers or military platforms like planes, ships, et. al. with the AEHF constellation. At this time, $1.3 million has been obligated. The 653 ESW/PK at Hanscom Air Force Base in Massachusetts manages the contract (F19628-02-C-0048, P00171).

June 26/09: Raytheon announces a successful test of their Advanced Multiband Communication Antenna System (AMCAS), developed for the U.S. Air Force. AMCAS is an extremely low-profile antenna that extends only 8 1/2”, and attaches to the aircraft’s metal skin rather than requiring complex in-fuselage installations. That configuration reduces drag, and minimizes time out of service during upgrades.

During the test, the AMCAS antenna communicated with the Milstar satellite’s medium data rate waveform, but it has been developed for use with FAB-T.

Oct 28-30/08: A successful system-wide Critical Design Review (CDR) for the FAB-T family. The Boeing Terminal Test team established log on, downlink, and uplink connections with a Milstar 6 satellite, as a first step toward implementing AEHF’s Extended Data Rate (XDR) waveform.

Formal qualification testing will now take place to validate the terminals’ interoperability and satellite interfaces, and Boeing expects to begin deliveries of engineering development modules to the Air Force in 2009 for FAB-T Increment 1. Flight testing of these modules is currently planned for mid-2009. Boeing release.

Sept 16/08: Boeing announces that it has delivered its FAB-T Increment 2 prototype to the Massachusetts Institute of Technology’s Lincoln Laboratory in Lexington, MA, ahead of schedule. The lab will use it to continue developing the DVB-S2 based communications waveform.

Waveforms define how radios, satellites, et. al. communicate. The Lincoln Lab’s efforts will define a waveform used for airborne intelligence, surveillance and reconnaissance readout over Ka-band military satellite communications. That waveform can then be incorporated in air, ground, maritime, and space communications equipment as required, as long as they have the required hardware or are software-defined and SCA-compatible.

Sept 4/08: A $16.7 million cost plus award fee contract modification to Boeing of Anaheim, CA to update new platform requirements and Advanced EHF (AEHF) system interface. At this time, $7 million has been committed by the Air Force Materiel Command,’s Electronic Systems Center, 653d ELSG/PK at Hancom AFB, MA (F19628-02-C-0048, P00146).

July 28/08: A $53.4 million modification to Boeing in Anaheim, CA, in order to update new platform requirements and FAB-T’s AEHF system interface. The Electronic Systems Center of Air Force Materiel Command manages the contract (F19628-02-C-0048 P00143).

April 9/08: Boeing received a modified contract for $25 million to incorporate Engineering Change Proposal (ECP) 0035, Strategic Networks, into the Family of Advanced Beyond-Line-of-Sight Terminals (FAB-T) Increment 1 program. At this time $9.25 million has been obligated, and the contract amount will be finalized later. Hanscom AFB, MA issued the contract (F19628-02-C-0048/P00141).

April 7/08: Cost increases for the AEHF satellite and FAB-T terminal programs land them both on the Pentagon’s latest Selected Acquisition Reports release:

”[FAB-T] Program costs increased $454.8 million (+14.4 percent) from $3,167.4 million to $3,622.2 million, due primarily to a revised cost estimate resulting from analysis by the OSD Cost Analysis Improvement Group (+$348.8 million). Costs also increased due to a net quantity increase of 6 terminals from 216 to 222 terminals (+$44.7 million), adjustments in real and predicated escalation (+$26.6 million), an increase in initial spares (+$25.5 million), and a net stretch-out of the procurement buy profile (+$9.2 million).”

Feb 15/08: Boeing of Anaheim, CA received a contract modification for $49.8 million. This undefinitized contract action to incorporate Engineering Change Proposal 0034, “New Platform Requirements and Advanced EHF System Interface Changes,” into the Family of Advanced Beyond-Line-of-Sight Terminals. At this time $17 million has been obligated. 653 ELSG/PKX at Hanscom Air Force Base, MA issued the contract (F19628-02-C-0048/P00138).

Feb 1/08: Northrop Grumman Corporation announces that it has demonstrated compatibility between the AEHF military communications satellite with user ground terminals using the new Extended Data Rate (XDR) waveform and protocols. Other future satellite communications programs, including the Transformational Satellite Communications System (TSAT) and the Enhanced Polar System, will also use XDR waveforms.

Earlier testing in May 2006 had already verified the backward compatibility of Advanced EHF with legacy terminals using Low Data Rate (LDR) and Medium Data Rate (MDR) waveforms. This latest demonstration included all 3, as 84 test objectives were demonstrated including links the U.S. Army’s Warfighter Information Network-Tactical terminal (WIN-T), the international variant of the Secure Mobile Anti-Jam Reliable Tactical Terminal (SMART-T), and Lincoln Laboratory’s Advanced Universal System Test Terminal (AUST-T).

Tests were conducted using a U.S. Army user terminal as well as a terminal configuration to be used by international partners, and included participants from the U.S. Air Force Space and Missile Systems Center,Northrop Grumman, the Joint Terminal Engineering Office, Lockheed Martin, the U.S. Army WIN-T program, the Lincoln Laboratory, and Raytheon (terminal manufacturer).

Sept 14/07: Lockheed Martin Space Systems Corp. of Sunnyvale, Calif. received a contract modification for mission software improvements amounting to $16.9 million. Element 1 covers a change order to modify the Mission Planning Element of the AEHF’s ground software, which models the AEHF’s communication plan, to accurately model and support both current and new AEHF terminals. Element 2 of these modifications will allow the Mission Planning Element to distribute transmission security keys for terminals using the Ultra High Frequency (UFO/ MUOS) Follow-On Enhanced Extremely High Frequency (E/EE) or Interim Polar satellite systems. Finally, 2 increments of the Mission Planning Element software being developed in parallel will be combined to create efficiencies in software development and maintenance.

Taken together, these software improvements will also mitigate the risk of incompatible planning tools between the United States and its International Partners in future coalition operations. At this time $8,470,148 has been obligated.

Sept 04/07 Boeing announces the first time that its FAB-T system acquires an operational Milstar satellite and completes downlink data transmissions. The Low Data Rate test meets program schedule commitments and lays the foundation for uplink tests and other interoperability assessments later in 2007. The test, conducted from Rockwell Collins’ FAB-T Systems Integration Laboratory, used Boeing, RCI, ViaSat and L-3 Communications integrated hardware and software products. Boeing release.

March 26/07: Boeing announces that their joint replan of the FAB-T program in conjunction with U.S. Air Force Space Command has earned the USAF’s Agile Acquisition Transformation Leadership Award. Approximately 300 of the program’s 700-plus requirements were changed, along with detailed schedule re-phasing for development, test, delivery and installation. Boeing claims that the replan delivered new capability, while ensuring that “strategic nuclear command and control connectivity remains uncompromised.”

The award, presented in February 2007 to the Space Command’s FAB-T Alpha Contracting Team at the annual Acquisition Leaders Forum in Atlanta, Ga., recognizes the joint government-industry effort for completing a significant replan of the FAB-T program in a record 10 weeks during the summer of 2006. The award also acknowledges skill in acquisition program management and leadership bringing about acquisition process transformation. Boeing release.

Feb 13-17/07: Team Boeing successfully completes a an external Critical Design Review (CDR) for FAB-T, paving the way for deliveries to begin. The CDR follows the recent delivery of a Block 4 software-defined radio to the U.S. Air Force, and successful Preliminary Design and Integrated Baseline reviews. Initial FAB-T deliveries will begin in December 2008.

A CDR needs to demonstrate that the program’s requirements are defined and understood to a point that gives the review board confidence in the team’s ability successfully execute a production contract. In this case key requirements included a survivable command and control capability for the next generation AEHF satellite constellation, plus demonstrated compatibility with the Extremely High Frequency Low Data Rate (EHF LDR) waveform, which forms the basis for future Advanced EHF (AEHF) waveforms and block upgrades. SCA-compliant EHF LDR compatibility also provides a base for hosting new waveforms being developed for the T-SAT (Transformational Satellite Communications) program. Boeing release.

Dec 11/06: ViaSat, Inc. finalizes a $35 million dollar subcontract modification with Boeing Integrated Defense Systems. This award adds additional technical requirements to the ViaSat FAB-T subcontract, and extends ViaSat product development and support through 2011. See ViaSat press release. To date, ViaSat has completed two major FAB-T program deliveries. Acceptance testing on the Prototype phase is complete and has been delivered to the U.S. Air Force as part of the Boeing team FAB-T terminal delivery. Boeing has also taken delivery of the FAB-T engineering development model hardware and software.

Nov 28/06: Lockheed Martin Space Systems Co. in Sunnyvale, CA received a $51 million cost-plus-award fee contract modification. This modification of the Advanced Extremely High Frequency (AEHF) MILSATCOM Systems Wing contract provides for transition from legacy Milstar ground control and mission planning equipment to new AEHF equipment. This realignment is necessary to account for delays in the delivery of new command post terminals, and the need to reduce the operational impact of the transition. This realignment also includes a program decision to upload the final planned increment of satellite software capability before launch rather than afterward, to avoid an interruption to future operations. The effect of these decisions is to extend the turnover date by 7 months for additional preparation and tests, though the launch date remains unchanged. At this time, $8 million have been obligated. Work will be complete May 2010.

Oct 17/06: Boeing has successfully completed a Preliminary Design Review for the FAB-T program, a key milestone. Attended in Anaheim, CA by more than 150 Boeing, senior government and industry officials, the four-day review included presentations from systems, software and hardware teams. Part of the key criteria were that Boeing and its industry team had to show that they had successfully incorporated schedule and requirement changes that are part of the program’s new baseline. See release.

Sept 27/06: Boeing Co. C3 Networks in Anaheim, CA received a $465.9 million cost-plus award fee contract modification. This modification will incorporate Engineering Change Proposal 0020 replan into the Family of Advanced Beyond-Line of Sight Terminals (FAB-T) increment 1 program. FAB-T terminals will connect soldiers or military platforms like planes, ships, et. al. with the AEHF constellation. The ECP 0020 replan addresses changes necessary to implement an executable program within cost and schedule objectives that will support AEHF requirements.

Specifically, the replan addresses the following: program overruns; requirements deferrals and accelerations; requirements deletions; pending requirements changes that will enable FAB-T to meet external requirements from concurrently evolving systems e.g., the AEHF payloads; and the INFOSEC module for FAB-1. The replan also includes the option to support government interoperability testing. Work will be complete December 2011. The Headquarters 653d Electronic Systems Wing at Hanscom Air Force Base, MA issued the contract (F19628-02-C-0048/P00095).

NB. The DefenseLINK release adds that “at this time, $1,761,770 have been obligated,” – which makes little sense as it is 4 times larger than the contract award. We’ve asked PA POC Monica Morales at (781) 377-8543 to clarify.

March 10/05: The NSA (National Security Agency) issued modified handling instructions during development, integration and testing of the FAB-T modem processor group, because of delays in their Cryptographics Verification and Design Verification testing of the ACTS cryptographic devices. In order to comply with the modified ACTS handling guidance, Boeing in Anaheim, CA received a $10.5 million cost-plus award-fee Undefinitized Contract Action (UCA) for Contract Change Proposal (CCP)-0011: ACTS (Security Chip) Handling procedures. This guidance requires physical security and emanation protection of the test facility, and will limit contact with the test equipment to personnel with appropriate clearances. The Headquarters Electronic Systems Center at Hanscom Air Force Base, MA issued the contract (F19628-02-C-0048, P00051), which is expected to end in September 2008.

Dec 21/04: The U.S. Air Force announces that the AEHF program has suffered a 1-year schedule slip, and cost growth of about 20%. The first launch of the 3 planned satellites is now slated for April 2008 rather than 2007 [Source]. In its release, the USAF cites:

”...unavoidable delays and cost growth due to delayed delivery of information-assurance [signal-encryption] products, and the resulting delay of terminals required for satellite command and control…. replacement of critical electronic parts and added payload component testing….”

Dec 8/04: The Boeing Co. in Anaheim, CA received a $42.5 million cost-plus award-fee contract modification for Family of Advanced Beyond Line-of-Sight Terminals (FAB-T), ECP 0011: Incorporated of additional Advanced Extremely High Frequency (AEHF) COMSEC/TRANSEC System (ACTS) chip and keying material delays into the FAB-T baseline; and update of FAB-T and AEHF baseline specifications. This contract modification incorporates both the most recent ACTS-related delays and synchronization with the maturing AEHF specifications. These modifications will be incorporated into 16 AEHF Engineering Development Models of terminals for the B-2, B-52, E-4, E-6, and RC-135 aircraft and for ground-fixed and ground-transportable command post terminals. At this time, $10 million has been obligated and work will be complete by September 2008. The Headquarters Electronic Systems Center at Hanscom Air Force Base, MA issued the contract (F19628-02-C-0048, P00040). The DefenseLINK release adds that:

“ACTS chip and ACTS keying material delays have occurred since FAB-T contract F19628-02-C-0048 award, driving schedule delays in both the AEHF and FAB-T schedules. In addition, AEHF system-level and inter-segment specifications have matured through working groups involving the government, Boeing, and the AEHF system contractor team.”

Aug 24/04: Boeing Co. in Anaheim, CA receives a $20.2 million cost-plus award-fee contract modification to bring FAB-T into line with changes in the AEHF specification. At this time, $2.1 million of the funds have been obligated, and work will be complete by December 2007. The Headquarters Electronic Systems Center at Hanscom Air Force Base, MA issued the contract (F19628-02-C-0048, P00028). The DefenseLINK release openly acknowledges that:

“At the time the FAB-T contract F19628-02-C-0048 was signed, the Advanced Extremely High Frequency (AEHF) specifications referenced in the contract were not complete and/or mature. Since that time, the (AEHF) system design and specifications have been maturing through working groups involving the Government, Boeing and the AEHF system Contract Team…”

Aug 04/04: The Boeing team announces completion of “a highly successful Preliminary Design Review (PDR) in Anaheim,” which included both systems-level and software reviews. See release.

Sept 24/02: The U.S. Air Force’s Electronic Systems Center (ESC) at Hanscom Air Force Base, MA announced Boeing as the prime contractor for a six-year, $273 million contract to design and develop the first increment of FAB-T. See release.

April 29/02: The Boeing Space and Communications Family of Advanced Beyond Line-of-Sight Terminals (FAB-T) team announces the delivery of their proposal. Boeing Space and Communications (S&C) is leading one of two industry teams competing for a 6-year, $279 million system design and development contract, which will be managed by the MILSATCOM Terminals Office at Electronic Systems Center, Hanscom Air Force Base, MA.

The proposal submitted by the Boeing team represents the first increment of the multi-phase program, where the winning team will have sole responsibility for a 6-year period of performance upon award in late June 2002. At the time of release, the initial design period is expected to be followed by the low-rate initial production phase in 2007, and the production phase in 2008. The system is expected to be fully operational by 2009. See release.

Additional Readings & Sources

• Lockheed Martin – Advanced Extremely High Frequency (EHF)

• Lockheed Martin – Advanced Extremely High Frequency Ground Station

• GlobalSecurity.org – Milstar-3 AEHF. The US Military Satellite Communications Systems Wing (MCSW), Space and Missile Systems Center informs DID that the Milstar-3 reference is not currently correct; AEHF is (now?) described as a follow-on system.

• C4ISR Journal (January 4/05) – First Launch of Advanced Communications Satellites Slips. About the AEHF.

• Boeing – Family of Advanced Beyond Line-of-Sight Terminals (FAB-T)

• US GAO (March 31/09, #GAO-09-36SP) – Defense Acquisitions: Assessments of Selected Weapon Programs [PDF].

• NDIA National Defense (September 2010) – Army Under Pressure to Bring Broadband to the Battlefield. Discusses JTRS rather than AEHF, but illustrates the wider trends and pressures.

• The Register (Dec 18/08) – US delays Royal Navy satellite comms project: Only 31 months late. The UK’s sub-based Naval Extremely High Frequency/Super High Frequency Satellite Communications Terminals appear to have the same problem as AEHF.

• Aviation Week (April 6/08) – USAF Plans First AEHF Launch. Then, early in 2009. It wouldn’t actually launch until Aug 14/10.

• Military Information Technology (June 13/05) – Network of Nations. Describes the U.S. military’s role as a satellite communications supplier to allies in Iraq.

• Marco Caceres of The Teal Group in American Institute of Aeronautics & Astronautics (AIAA) Industry Insights (January 2002) – Military satellites: The next generation

• Crosslink Magazine (Winter 2001/2002) – Future U.S. Military Satellite Communication Systems. Excellent overview and very informative graphics.Covers planned systems to 2010.

• TelecomWeb ViaSatellite.com articles. See esp. “The Military Sector: Doing Business With The Decisionmaker” [Part I | Part II]. Part I describes current US satellite programs and trends, while Part II focuses more on the doing business aspect.