What We Do

MacB’s antenna positioners are designed for use with flat panel antennas and incorporate a custom RF deck. They accommodate small parabolic reflectors and horns and feature simple but rugged drive systems that deliver low backlash, high stiffness and high reliability. A Java-based GUI provides real-time, in-depth command, control and communication capabilities.

• Drivetrain – DC motors with gearheads on azimuth and polarization, belt drive
  on elevation
• Control Electronics – Fully integrated and controlled via computer
• Sensors – GPS, compass, inclinometers, motor encoders, limit switches and optional GPS differential compass
• Material – Machined and anodized aluminum
• Antenna/Payload Mounting – Custom quick release antenna mount
• RF – Integrated wideband RF deck along with IF input peak detect within a
  scan window

Customized to customer needs, our Custom Camera Integrations include both high resolution still frame cameras and high frame rate video cameras. Camera modules have been integrated into miniaturized pan/tilt units for dynamic surveillance applications. Multiple imagers have been arrayed together to provide full 360° coverage of an environment. Ultra-miniature focus modules have been included on chip-level imagers to provide a broad depth of field and sharp focus on the desired target of interest. Control of camera systems include wired and wireless standard interfaces such as TCP/IP and WiFi as well as customer proprietary control links.

Features:

• Broad range of possible cameras
• Pan, tilt, zoom and focus with precise motion control and remote interfaces
• Store and recall any camera settings including location and lens position
• Array of multiple imagers with image stitching technology provides full view
  of environment
• Available in color, monochrome, low light or integrated with custom illuminators
• Captured data available in a variety of formats

Our electrical engineering expertise runs the gamut from high speed digital applications to high power motor control and everything in between. We are the leader in design and integration of complex technologies, including:

• RF digital, analog and embedded circuit design (Microcontrollers, FPGAs, etc.)
• Custom power management, including unique battery solutions and specialty power supplies
• Digital motion control and positioning systems
• Smart sensor system design and integration, including seismic, thermal and barometric extending to multi-modal or “fusion” implementations
• Video, audio and other surveillance systems
• Standard and custom communication interfaces

Since MacB’s inception more than 36 years ago, we have been providing Electronic Warfare (EW) services and product solutions covering the full range of Electronic Attack (EA), Electronic Protect (EP) and Electronic Support (ES) capabilities. The Department of Defense (DoD) relies on our EW expertise to support the Nation’s most critical EW initiatives and weapon systems. We design, deliver and support techniques and equipment that prevent the use of the electrometric (EM) spectrum by our enemies. Our EW expertise helps protect critical assets against enemy employment of electronic warfare that could degrade, neutralize or destroy friendly combat capability, while allowing us freedom of action across the EM spectrum.

With top-secret level manufacturing and design facilities in Dayton and Northern Virginia, we are uniquely qualified to provide secure, rapid fabrication services for sensitive requirements. Throughout our history, we have been at the forefront of developing the tools and systems used by intelligence and military personnel throughout the world.

We provide: physical reverse engineering; tailored inclusions and total device reproduction; custom design and fabrication of OEM and legacy items; natural Item replication: trees, limbs, rocks; Rapid Prototyping – in-house 3D Printing; Custom Wood and composite wood-like items; Structures with precisely controlled RF transparency; Comprehensive Machine Shop: Common structural and exotic metals, hard-tool mold making; Plastics Fabrication: Vacuum cast, pressure cast, injection molding, rotational molding; and Composites: Including heat and ballistic protection.

In addition, we have mastered the embedding of electronic circuits into almost any material or host device. Our polymer fabrication facilities utilize urethane vacuum casting, injection molding, pressure molding, rotocasting and can include composite layups. Utilizing a patent pending MacB-designed system and process, we offer the ability to fully embed electronic systems in rotationally molded parts. This facilitates deep sensor embedment in new materials and a virtually unlimited range of molded plastic items: military, industrial
and commercial.

• Fully encapsulated electronics, antennas and power supplies
• Enables more sophisticated sensor and sensor-to-trigger solutions
• Supports passive data collection / sensor systems
• Replicates a huge variety of potential hosts
• Durable in very harsh operating environements over long time periods

Today’s Department of Defense (DoD) systems often have operational life cycles that span multiple decades. Most of these systems utilize microelectronics, including FPGAs, that have significantly shorter life cycles than the overall systems and become out-of-date or even obsolete while the system is still in production. MacB offers design recovery and retargeting as an alternative to redesign for obsolete programmable logic components in aging U.S. DoD systems.

With a unique capability, we translate a binary program¬ming file of a digital logic device into a human readable, retargetable circuit description. This automated process helps to reduce cost, schedule, and risk by offering a simple path from an obsolete part to a maintainable component in critical systems. MacB focuses these services on the commercial-off-the-shelf (COTS) logic-bearing integrated circuit known as the Field Programmable Gate Array (FPGA) and the case where the design source or tools may not be available.

MacB maintains dedicated space to produce hardware systems in small lots, with production quantities varying from a handful to several hundred.  These facilities accommodate multiple material types and includes the capabilities:

• Comprehensive machine shop (milling, turning, EDM)
• Automated PCB population, wire harnesses, RF cables and lithium battery packs
• Composite materials from wood to carbon fiber
• Injection molded and vacuum cast plastics
• Finishing including paint, powder coat and accelerated aging

The MacB mechanical engineering team is comprised of experienced engineers and designers with diverse technical backgrounds. Through the use of modeling and analysis tools, we create detail designs, assemble prototypes and test our product solutions to ensure they meet the high standars our customers demand. We have been at the forefront of producing unique tradecraft solutions in the areas of: Integrated Sensors, RF, Acoustic & IR Suppression, Positioning Systems, Drive Mechanisms, Special Hand Tools and Power Tools, Custom Installation Kits, Drilling Technology and Design & Drafting.

The Powerpuck is a breakout module for a BA-5590 battery. The unit provides multiple regulated voltage levels, as well as battery pass through to various connector types. Two LEMO style connectors as well as two Tajimi style connectors are available with user settable outputs of regulated 5V, regulated 12V or Battery Voltage. A standard USB jack and terminal block are also included to facilitate connection to commercial equipment. The module also provides graphical LED readouts for current battery voltage and current draw. A Velcro strap is provided to positively attach the unit to its host battery.

–The breakout module plugs directly into the top of the battery.
–The module is secured to the battery via Velcro strap.
–Modular connectors are grouped into pairs of two. The switch directly above the connectors controls the voltage output of the connectors below.
–The terminal block located on the side of the module is controlled by the switch located on the same side.
–Voltage selector switches are recessed to resist inadvertent changes.
–LED bar graphs provide real-time status of battery terminal voltage and
current draw.

The MacB Alexandria-based Prototyping Lab is used by integrated product development teams to evaluate concepts and quickly deliver solutions to the field.  We have the following capabilities at this lab:

• Engineering CAD tools for modelling, simulating and virtualizing:
–Systems (Matlab)
–3D mechanical systems (Inventor and SolidWorks)
–Electronics (Altium)
–Finite Element Analysis (Ansys)
–Fluid Dynamics (CFD)
–Electromagnetics (HFSS)
• Reverse Engineering with FARO arm, XRAY inspection and optical comparators
• PCB prototyping tools (LPKF) for circuit and antenna prototypes
• 3D printers (multiple technologies and materials)
•   Laser cutters and etchers, WaterJet

The ability to test and evaluate our systems against realistic threats is a critical step in the development of the DoD’s Electronic Warfare and Sensor development process. Yet it is often difficult to schedule the ranges, labs or the equipment necessary for adequate testing or verification.

To help resolve this problem, MacB worked with the Air Force Research Laboratory (AFRL) to design, develop, build and deploy the Re-Locatable Jammer (RLJ) system using a Field Programmable Gate Array (FPGA) based Digital Radio Frequency Memory (DRFM) and advanced Digital Signal Processing technology. Several RLJ units now exist that can be deployed virtually anywhere, from laboratories to open air ranges, to facilitate testing efforts. The units are built by MacB and owned by AFRL.

We have mastered the embedding of electronic circuits into almost any material or host device. Our polymer fabrication facilities utilize urethane vacuum casting, injection molding, pressure molding, rotocasting and can include composite layups. Utilizing a patent pending MacB-designed system and process, we offer the ability to fully embed electronic systems in rotationally molded parts. This facilitates deep sensor embedment in new materials and a virtually unlimited range of molded plastic items: military, industrial and commercial.

• Fully encapsulated electronics, antennas and power supply
• Applicable to more sophisticated sensor systems and sensor-to-trigger solutions
• Enables new missions / targets
• Supports passive data collection / sensor systems
• Durable in very harsh operating environments over long time periods

MacB SCC is fully accredited as a Trusted Integrated Circuit Supplier to Trusted Category 1A. As a trusted supplier, accredited by the Defense Microelectronics Activity (DMEA), we are certified as a trustworthy design service provider. Our Secure Computing and Communications Lab consists of 12,000 square feet that encompasses state-of-the-art electronics, reverse engineering, and software development facilities to deliver rapid prototyped hardware and software for quick proof-of-concepts, as well as creating, integrating, and testing production quality products for maximum traceability, accountability and stability.

We maintain in-house expertise for developing EDA tools, GUIs for data visualization and process management, embedded code, device drivers for Linux and Windows, Linux kernel modifications, high-speed data acquisition, web-enabled collaborative tools, and clustered computing. In addition to custom developed tools, MacB engineers leverage industry leading third-party EDA and reverse engineering tools for simulation (e.g. Mentor Questa), formal verification (e.g. OneSpin 360), synthesis (e.g. Synopsys Synplify), debugging tools (e.g., Synopsys Verdi), and software reverse engineering tools (e.g., IDA Pro).  We maintain expertise in C/C++, C#, VB.NET, Java, Python, PHP, and ASP.NET.

We are experts at integrating sensors in support of Human Intelligence (HUMINT), Signal Intelligence (SIGINT) and Intelligence, Surveillance and Reconnaissance (ISR) missions. State-of-the-art modeling tools, combined with cleared personnel and facilities, are ideal for embedded system, reverse engineering, simulation and replication support.

• Deep bench of engineers, craftsmen and technicians experienced in
  sensor integration.
• Quick Reaction Capability (QRC) to support rush requirements.
• Metal, plastic, composite, wood and electronics fabrication.

Software development is a complex process. We employ a team of certified and experienced software engineers, many of whom have spent more than a decade working on government systems. To meet the needs of our customers, we have created a system development methodology that addresses high risk items, incorporates requirements for tracking and iteration checks, and continuously tests the system to ensure that the overall software architecture supports all changes.

Our methodology includes Agile Software Development, which adapts to high-quality short iterations, resulting in quick-turn fielded capabilities. MacB’s proven methodology ensures that detailed acceptance criteria are well defined and traceable to the requirements, and also account for throughput, security, training, long-term maintenance, quality, the test environment and any interoperability considerations. Our Information Solutions Division (ISD) has more than 10 years of experience executing MacB’s system development processes, and is appraised at Capability Maturity Model Integration (CMMI) Maturity Level 3. Additionally, the Exceptional Contractor Performance Assessment Reporting System (CPARS) and follow-on software efforts, are the direct result of applying our mature processes with excellent engineering teams. These successfully processes result from really listening to customer needs.

We perform in-house development and final verification and validation testing of all products in our extensive and secure laboratory facilities, such as the Wright Innovation Lab in Dayton Ohio. Our test engineers implement Department of Defense (DoD) and customer-specific tests utilizing an array of state of the art test equipment shown below. Our test facilities reduce product development time, improve product performance in anticipated operating environments, and provide the ability to test sensitive items in a quick-reaction setting.

Test Plans are developed to utilize both internal capabilities and manage extended testing through third-party labs as required. Subject matter experts follow industry best practices in developing test procedures, conducting tests, and reporting test results to our clients.

Globalization of the technology supply chain has changed the way the Department of Defense (DoD) approaches the trustworthiness of complex critical systems. In the past, much of this trust was based on the fact that critical systems and their components were designed and manufactured within the US by cleared personnel. Systems were also simpler with less reliance on multi–function integrated circuits. But times have changed. The use of integrated circuit technology across the world has increased dramatically, and the market for critical integrated circuit technologies such as Application Specific Integrated Circuits (ASICs) and field-programmable gate arrays (FPGAs) is no longer dominated by DoD.

Due to this market evolution, DoD neither controls production nor drives the requirements of leading-edge devices. Even in situations wherein production can be controlled, such as through the use of the DoD Trusted Foundry, modern integrated circuit designs are so complex that they are typically composed of third–party intellectual property (3PIP) circuit cores of unknown provenance. They are often designed, synthesized, and validated by electronic design automation (EDA) software developed overseas. In addition, the components are often integrated onto printed circuit boards (PCBs) for commercial-off-the-shelf (COTS) electronics at overseas manufacturing facilities, prior to entering the U.S. market. Thus, even with ostensibly trusted processes of production, DoD systems and their software, firmware and hardware components are susceptible to counterfeiting and malicious tampering.

The MacB approach to supply chain security includes a comprehensive assessment of the system and its subcomponents throughout their lifecycle. We have a well-established history of providing support for security, cyber threat, integrity, and vulnerability analysis, as engineering services to our government customers. MacB is accredited by Defense Microelectronics Activity (DMEA) for Category 1A Design Services in the Trusted Integrated Circuit (IC) Supplier Program. Our subject matter experts help deter, detect, delay or react to the compromise of these systems. As an independent evaluator, we can work with the developers, system integrators, and operators to verify that the development, manufacture, and deployment of the system has properly identified and protected the mission-critical functions and critical components.