MCH-100-A BATTERY POWERED HEAT GUN KIT

MCH-100-A HEAT GUN

Customer

U.S. DOD

Partner(s)

Leister, Bren-Tronics, Fieldtex, J & J technologies, Skydyne

Applications

Shrink Tubing, Soldering

Industries

Aerospace, Aviation, Electronics

SOLUTION

The MCH-100-A Battery Powered Heat Gun Kit, NSN: 4940-01-475-2026, includes the 111.038.1 Heat Gun, a powerful 42 VDC Battery Powered Heat Gun with two interchangeable nozzles for shrinking and soldering and temperature capabilities ranging from 500F to 950F, dependent on nozzle and heating element choices. Temperature ramp-up from ambient conditions is 60-90 seconds with a continuous run time of 30-35 minutes depending on environmental conditions the tool is used in.

The Heat Gun is powered by the MCH-102NW Power Supply that utilizes two standard Department of Defense BB-390B/U Nickel Metal Hydride smart batteries capable for redeployment within 2 hours of simultaneous charging on the kit included multi-voltage input BTC-70819 SPC Lite Fast Charging System.

Designed and tested to perform in harsh rain intrusion and salt fog environments, and to exceed Military Standard Requirements for use in explosive atmospheres, zero electromagnetic interference environments, and in robust handling battle deployment situations, the MCH-100-A is the only tool in its class approved for use on fueled aircraft by NAVAIR. Additionally, the MCH-100-A eliminates the need for an auxiliary power unit in quick avionics repairs and increases safety factors by eliminating power cable spreads and open flames on flight decks.

MCH-100-A Downloadable Specifications

MCH-100-A Downloadable Components and Accessories

MCH-100-A You Tube Video on Battery Management Procedures

Development

In 1999, Malcom developed a portable heat gun for the US Navy Aviation Ground Support Equipment Team​ at NAVAIR to shrink and solder avionics on fueled aircraft in the harsh battle conditions of deployed Aircraft Carrier Flight Decks. Current tools required a powerline spread, an auxiliary power unit, or open flame, which led to extended grounded aircraft times and often infringed on safety standards. The next generation heat gun would need to be a portable, handheld, robust, powerful, and adaptable tool capable of operating in wind, rain, salt-fog, desert, arctic, explosive atmosphere, and electromagnetically sensitive environments.

Malcom responded in less than 2 months with a functional Commercial Off the Shelf (COTS) Proof of Concept design that successfully soldered and recovered avionic shrink sleeves. The design utilized a COTS 42 VDC Heat Gun, manufactured by the Swiss based worldwide leader in heat tools Leister, and a COTS NiMH Battery System, manufactured by the US based Army SINGARS supplier of NiMH batteries Bren-tronics. Latter design iterations included an EMI shielded thermoset fiberglass battery case, manufactured by the US Based Skydyne Company

Testing

With functional success, NAVAIR began testing units in the field. User feedback, operational testing, and MIL-STD directed engineering informed further design optimization.

MIL-STD testing conducted:

  • MIL-STD-461E EMI Control, RE101
  • MIL-STD-810F Environmental Tests
    • 511.4 Explosive Atmosphere
    • 506.4 Rain Intrusion
    • 509.4 Salt Fog
    • 516.5 Shock

DELIVERY

Within eight months of Proving the Concept and multiple optimization iterations, Malcom delivered fully qualified First Article MCH-100-A Battery Powered Heat Guns to the NAVAIR team. Three months following the initial contract award and eighteen months following the initial design consultation, Malcom delivered 250 tools to the Navy for deployment. NSN: 4940-01-475-2026

Currently, Malcom has delivered nearly 3,000 MCH-100-A and MCH-100-AB Battery Powered Heat Gun Kits to all branches of the Department of Defense, including the Navy and Marines, Air Force, Army and National Guard, as well as NASA and Homeland Security, and industrial customers in the Aerospace, Energy, Manufacturing, Research and Maintenance sectors. Innovation continues as new applications demand and has resulted in developing the MCH-100-C, a low cost Battery Powered Heat Gun, and accessories such as the MCH-116 Soldering Iron, the MCH-100-HMD Hot Melt Iron, and MCH-100-HB Hot Bonder.