ASRC Federal’s redesign of the SINCGARS radio handset shows what’s possible when speed, innovation and digital engineering converge. In under a year, the ASRC Federal team transformed an aging but essential communications asset into a modernized tool built for today’s operational demands.
The Challenge: Legacy Tech in a Rapidly Changing Mission Environment
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SINCGARS has long served as the U.S. military’s primary combat‑net radio—connecting forces across ground, air, and maritime missions.
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Traditional engineering timelines for redesigning critical equipment can stretch years, delaying delivery of new capability to the warfighter.
The Breakthrough: Speed to Delivery Through Digital Engineering
ASRC Federal applied digital engineering and additive manufacturing to compress years of work into months. Key accelerators included:
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Reverse engineering of the legacy handset
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Digital modeling for faster validation
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Additive manufacturing for rapid prototyping and production
“We used rapid prototyping to iterate very quickly on our design. At the end of the day, we delivered an amazing product that the customer valued greatly. In fact, we delivered it nine months early. – Cory Hansen, Sr. Principal Electrical Engineer”
The Outcome: A Smarter, Mission‑Ready Handset
In less than a year, ASRC Federal has tested, qualified and delivered more than 2,600 new and improved SINCGARS handsets.
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Lighter, smarter and fully qualified for real‑time operations
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Designed to improve coordination, readiness and mission effectiveness
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Ready for training and combat environments across services
The rapid SINCGARS redesign isn’t just an engineering success—it’s a blueprint for how industry can answer the DoW’s call to get modernized, mission-essential technology in the hands of warfighters quickly and affordably.
