ARNOLD AIR FORCE BASE, Tenn. -- As he detailed the response of Arnold Engineering Development Complex team members to an urgent test need, one word frequently found its way into Lt. Col. Joe Sabat’s account – unprecedented.
From the time the request was fielded to the point at which test data was delivered by members of Team AEDC, fewer than three days had rolled off the calendar.
The execution of this accelerated test demonstrated ability of AEDC to respond to urgent warfighter needs and deliver mission-critical results with speed and collaboration, said Sabat, previous commander of the 716th Test Squadron at Arnold Air Force Base, headquarters of AEDC.
Earlier this year, the 96th Test Wing at Eglin Air Force Base, Florida, submitted a high-priority test request to the 716 TS. Wing officials called for the 716 TS to conduct a loads test characterizing the integrity of F-16 Fighting Falcon flight envelope with a new weapon system in carriage.
This data, Sabat said, was vital in assessing the structural integrity of the new system and ensuring warfighter safety during its wartime employment.
The test article needed to be delivered in less than 48 hours. To meet this challenge, AEDC personnel adopted what Sabat referred to as a “multi-pronged strategy” to both accelerate and reduce risk during the article manufacturing process.
“To ensure they could meet the deadline and avoid a complete stop due to any potential challenges, the team pursued three parallel manufacturing paths simultaneously,” Sabat said.
The Arnold AFB Model and Machine Shop, which falls under the purview of the 804th Test Support Squadron, immediately began fabrication to support the test. Almost concurrent to these efforts, a local business was awarded a contract to design and machine a model. Meanwhile, the 804th Test Group Project and Design Team collaborated with the U.S. Army Combat Capabilities Development Command Aviation & Missile Center at Redstone Arsenal, Alabama, to additively manufacture, or 3D print, two metal test articles.
Sabat said this “all hands on deck” approach ensured that, even in the face of an extremely tight schedule, the required hardware was ready for testing.
“All three manufacturing paths produced a quality test article within two days but, ultimately, the 804 TSS Machine Shop produced the first available model that was used for air-on testing,” he said.
When the test request came in, there was “zero hesitation” on the part of the Model Shop team, according to 804TSS Director Dustin Boss. The team there quickly took an engineering model, developed the machine program, acquired material and formed the scale model test article in less than 24 hours.
“That took significant personal sacrifice, with team members immediately shifting their work schedules and working through the night to make this happen,” Boss said. “This incredible display of dedication and skill highlights the remarkable talent and capability the Air Force has at the AEDC Model Shop.”
Boss added the Model Shop team executed the effort flawlessly.
“Delivering a completed model with such speed demonstrates the unmatched rapid-response capability the Model Shop provides,” he said. “Our team has a well-earned reputation for excellence, and by delivering the first available model ahead of the other parallel manufacturing paths, they proved exactly why they are trusted with our most critical missions.”
After assessing the information requested by the 96th Test Wing, a team of subject matters experts comprised of Marvin Sellers, J.T. Thompson and Nolan Murray developed a test plan to acquire the necessary data.
“Our experiences led us to utilize the Aerodynamic Wind Tunnel 4T sized F-16 test article to acquire the aerodynamic loads,” said Sellers, who served as lead test engineer for the effort. “The F-16 and support hardware existed in inventory, but the store did not. J.T. and Nolan located the equipment necessary for testing, and I worked to get a model designed for fabrication before the first day ended so fabrication could be started just after midnight in the AEDC Model Shop. The design was also sent out to one manufacturer and the additive manufacturing group that night.”
Sellers added tests in Aerodynamic Wind Tunnel 4T typically require months of preparation, along with technical and safety reviews, prior to commencement. He credited the test manager and 716 TS Analysis Flight Chief Nissa Schuman for taking care of the funding, project planning and achieving “some exceptional feats” to get the outside vendors onboard on short notice.
“We did not skip on either of the reviews, but everything else was ‘perform only what is minimally required’ to test on the third day and meet the data need date,” Sellers said. “Everyone who worked on this effort was willing to go beyond normal work schedules to make this come to fruition. The team effort was exceptional.”
Members of Team AEDC began air-on operations in 4T only 46 hours after the initial test request was received.
“In my 45 years of testing at AEDC, I have only seen one other effort similar to this and that was in support of Desert Storm,” Sellers said. “For that test, I only had four weeks to get the F-15 and F-16 ready to test a new store, both aerodynamic and separation, with completion on Christmas Eve. We succeeded then also, but this effort was in another league.”
Kenneth Ligon, an AEDC engineer who acts as 4T Crew Chief, said preparation was key in the effort. The Test Cell Crew Chief program was launched at Arnold AFB in 2025, and test cell crew chiefs act as a single point of accountability for operational readiness, safety and performance in their assigned facilities.
“The engineers at 4T take pride in our work and are heavily involved in tunnel maintenance and test build-up and installation activities,” Ligon said. “We try to practice good housekeeping, ensure we have adequate tools to perform the work, keep a detailed inventory of systems and test hardware, keep sufficient spares on hand, be proactive about repairing tunnel and support system issues, and take every opportunity to make test cell improvements. I think these habits put us in a good position to respond to any challenge, regardless of timeframe.”
The undertaking further exemplified the definition of “team effort,” Ligon added.
“There are so many people involved in the planning, build up and execution of these programs,” he said. “To not have a model and then come air-on 46 hours later takes everybody to work effectively. It’s nice to see everybody come together in a quick timeframe to do something ‘impossible.’ I would like to give a special thanks to Mr. Barry Benson for his support.”
The article was not the only thing tested during the operations. Sabat said the team’s resilience was also put to the test when a water leak was discovered in the tunnel compressor cooler.
“The operations team immediately came offline, diagnosed the issue and reconfigured the facility around the leaking section to resume testing in under four hours, preventing a significant delay and ensuring all primary test objectives were met,” Sabat said.
Quick-look data products were delivered to the 96 TW only 67 hours after the request was sent.
“The data fulfilled the primary requirements and provided insights into the weapon’s performance at high speeds caused by shockwave formation,” Sabat said.
Sabat lauded the team of more than 180 personnel across AEDC involved in the effort for the speed and ingenuity they displayed to quickly deliver the critical test data.
“The team showed unprecedented responsiveness to the urgent request,” Sabat said. “It’s a humbling honor to be involved with teams that can mobilize to accomplish a test mission like this. The unhesitating support from the entire AEDC, Redstone and Tullahoma teams was eye-watering.”