Advanced Metalworking Solutions for
Naval Systems that Go in Harm's Way

Low Cost Pallet Systems Phase II


The second phase of this project demonstrated the various improvement recommendations in a series of representative prototype sample builds.  Overall, the primary objective of the project was to reduce manufacturing cost and system weight of the AGS pallet assembly by 10 percent ($35.4K per pallet) without compromising system performance.


DDG 1000 will be equipped with two Advanced Gun Systems (AGS) manufactured by BAE Systems. Both systems utilize the EX-813 AGS pallet to package, handle, store, and transport the Long-Range Land Attack Projectile (LRLAP) munitions and charges through the Navy logistic channels and within the AGS magazine in the DDG 1000 hull. The first phase of this project culminated in a set of recommendations and accompanying technical data package of potential product manufacturing improvements.

Technical Approach

The project focused on manufacturing a sample of the leading set of manufacturing improvement recommendations to confirm the manufacturing costs and to validate the functionality of the article.


The project achieved a 12 percent reduction in manufacturing cost, which equates to a $6M per hull savings (150 pallets per hull @ $41K per pallet), and a 190-pound-per-pallet reduction in system weight that will improve the safety and survivability of the AGS pallet system.


The Navy Metalworking Center (NMC) optimized the selected manufacturing approaches developed during Phase 1, including improved gas tungsten arc welding joint design and welding techniques, along with advanced machining and casting of critical projectile and propellant assembly system parts. The project produced a prototype AGS pallet system, and a Technical Data Package of proven manufacturing improvements and cost reductions was delivered to BAE Systems and NAVSEA PEO IWS 3C in November 2010 for implementation into the Low-Rate Initial Production (LRIP) of the AGS Pallet System in FY2011.




Bryan Baudler
AGS / LRLAP Acquisition Program Manager


BAE Systems
Naval Surface Warfare Center, Dahlgren Division
Naval Surface Warfare Center, Port Hueneme Division
PEO IWS 3C Naval Gunnery Project Office