New 578-foot Mach 1 ground-based sled track trains vital F-35 shields for US pilots

The U.S. Navy has opened the nation’s first ground-based sled track designed to test aircraft countermeasures at speeds reaching Mach 1. Naval Surface Warfare Center Crane developed the facility with the Indiana National Guard at Camp Atterbury. Officials unveiled the new capability on August 12. The track will help engineers evaluate airborne expendable countermeasures before moving them into costly flight tests. NSWC Crane expects the approach to shorten development cycles and save about $1.7 million each year. Engineers can now subject countermeasure systems to extreme forces without putting aircraft and aircrew into early-stage evaluations. The Navy also expects more mature systems to enter later flight testing. High-speed testing tube The facility uses a 578-foot steel track with a 402-foot opening. Its interior features a graphite coating designed for demanding high-speed testing. NSWC Crane has validated the system at speeds up to Mach 1. Advanced imaging equipment records infrared countermeasure performance during each run. That capability matters because aircraft countermeasures must operate under intense physical conditions. Ground testing gives engineers a controlled environment where they can repeat runs and quickly examine the results. Dr. Angela Lewis, NSWC Crane’s technical director, said the facility will allow faster engineering iterations before systems reach aircraft testing. “It allows us to rapidly iterate, optimize designs on the ground, and deliver highly mature, reliable countermeasures,” Lewis said. The track will support programs across several military aircraft. Those include the F-35, F/A-18, F-16, MH-60, and C-130. Faster path to flight Flight testing remains essential, but it consumes aircraft time and requires complex scheduling. Early ground-based testing could remove some of those bottlenecks. NSWC Crane expects engineers to identify problems sooner and refine designs before requesting aircraft support. The facility will also support Lot Acceptance Testing for different countermeasure specifications. That could create a more consistent testing process across multiple programs. It also gives the Navy another way to accelerate technologies intended to protect American aircrews. Rep. Erin Houchin said the new capability could improve safety while reducing taxpayer costs. “Opening this first-of-its-kind Sled Track Facility provides a critical new capability for testing and evaluation,” Houchin said. “It ensures we are delivering the best technology to protect our aircrew.” Camp Atterbury now becomes part of a testing effort that connects the Navy, National Guard, and defense industry. The site’s existing ranges will support work aimed at moving critical systems toward operational use. Indiana expands defense role Indiana Gov. Mike Braun called the project another sign of the state’s expanding defense technology sector. “Indiana continues to lead the nation in defense innovation,” Braun said. He pointed to the partnership as an investment in safer and more advanced equipment for U.S. service members. Maj. Gen. Larry Muennich, Indiana’s adjutant general, said Camp Atterbury’s ranges now contribute directly to technology development alongside military training. The Navy hopes that formula will speed the arrival of new countermeasures while giving U.S. aircrews an additional layer of confidence before taking to the skies.Get the latest in engineering, tech, space & science - delivered daily to your inbox.Aamir is a seasoned tech journalist with experience at Exhibit Magazine, Republic World, and PR Newswire. With a deep love for all things tech and science, he has spent years decoding the latest innovations and exploring how they shape industries, lifestyles, and the future of humanity.