Celebrating 75 years, Dayton T. Brown, Inc. accelerates aerospace and defense testing, certification and next-generation space technologies
When Dayton T. Brown Senior founded his company in 1950, he was already a pioneer in aviation after graduating from the Massachusetts Institute of Technology, designing aircraft and working with large companies such as Detroit Aircraft, the Brewster Buffalo Company and Northrop Grumman. Dayton T. Brown, Inc. (DTB) began manufacturing small components for the aerospace sector and working on numerous projects for the Navy, which kickstarted the company’s testing and engineering division – described by President, Jim Kelly, as the cornerstone of the organization. Rapidly evolving into an established sheet metal manufacturer, the corporation eventually transitioned into a manufacturer’s partner to help them achieve certification, and today, it collaborates with cutting edge companies including SpaceX, Blue Origin and Lockheed Martin Corporation.
As DTB celebrates a significant 75-year milestone, Jim joins Manufacturing Today, along with his colleagues Matt May, VP & Division Manager in Testing & Engineering, and Ivette Damish, SVP in Corporate Sales & Marketing, to discuss how its partnerships, facilities and innovations have progressed over the decades. “Our work revolves around new product introduction (NPI) and it starts early in the design process,” Ivette starts. “This means we have NDAs with most of our partner companies, and we regularly see the products included on TIME’s Best Inventions of the Year list. These new trends are exciting; it brings passion and it drives what we’re doing.”
“We’re constantly innovating and this is the reason why giants such as SpaceX and Blue Origin work with us,” adds Jim. “We can match them and help with certification processes. Our partnership steers their products towards supporting missions, as most of it is mission critical; aerospace, defense – applications that are protecting and supporting the world. The partnerships drive us even further.”
Headquartered in Bohemia, New York, the company operates more than 300,000 square feet of test laboratory space and maintains additional facilities throughout the US, including locations in Alabama, Florida and Maryland. “Our facilities are literally endless and we’re constantly adding to it as the market changes and the need grows in certain areas,” highlights Matt. “Here in Bohemia, our capabilities range from dynamics and environmental, to structurally testing full aircraft and ensuring flight safety. We have electromagnetic interference (EMI) and electromagnetic compatibility (EMC) testing sites, and we also have a ballistics range for testing armor and windows of airplanes and military parts.” Huntsville, Alabama, is primarily for rocket motor testing, compression testing, hydroproof and burst testing, and X-ray inspections. Expanding in phases to address the Department of War’s rapid deployment needs, additional capabilities in DTB’s Huntsville site will include vibration, environmental, and EMI/EMC to test defense component requirements.
Merritt Island
Meanwhile, Merritt Island, Florida, is purpose-built for space and satellite testing. “We have a big clean room area in Merritt Island where we conduct vibration testing, environmental, EMI/EMC, and a thermal vacuum where we simulate the harsh space environment by combining high vacuum with extreme temperature cycling. Quite often, we’re the last people ever to handle these parts before they launch into space,” Matt continues. The Pax River location in Maryland, which is home to DTB’s mission systems division, is where mobile Sensitive Compartmented Information Facilities (SCIFs) are designed and purpose-built for different Department of War missions. DTB’s Maryland location also performs logistics and warehousing functions, sourcing strategic materials and performing inventory management with rapid deployment while monitoring quality and cost. The DTB team deploys worldwide to maintain the SCIF fleet while fulfilling logistics needs.
State-of-the-art facilities go hand in hand with advanced technologies. “My BSc is in computer science,” reveals Jim. “I’ve been a programmer for a big part of my life, and I’m constantly involved with technology – I believe in being totally digital.” From an AI perspective, the organization is exploring how to improve efficiency and further help customers, which Jim labels ‘critical’ as it pursues an engineering design guidance engine and continues the development of its DTB Edge software. “We’re trying to capture 75 years of data, analysis and experience in an AI model that can help manufacturers release products into the marketplace sooner and to missions sooner, while still going through the rigorous testing it needs to qualify,” Jim explains.
Alongside working on AI integration, Dayton T. Brown, Inc. is heavily involved in the Golden Dome missile defense system as a testing partner in several aspects. The Advanced Structural Integrity and Pressure (ASIP) facility in Huntsville is built specifically to develop specific test systems for critical components, like rocket motors, allowing proximity to the customer. “We value our customers as partners,” Ivette states. “We’re here to help them; we listen to their needs and requirements, and then we support their needs through partnerships and execution. It’s an evolutionary process and we take that approach with every single customer.”
Partnering with Airbus for LaunchOne is another ongoing project. “It’s very exciting and we have a unique relationship with Airbus,” emphasizes Jim. “Testing for space in Merritt Island means we’re close to the launch sites.” The vision for LaunchOne is one contract and one facility by a dedicated team of professionals capable of supporting customer qualification for space missions. Maximizing the LaunchOne services in Florida is a priority for the company, along with scaling up Huntsville, both of which will have a significant impact on the Missile Defense Agency and space industries. “This will really set the bar for our future objectives,” Jim continues. “These are critical initiatives and we plan to have them up and running by the summer. We want to be the gold standard as an independent test lab and logistics provider.”
Manufacturing requires technical documentation and DTB answers that need with its technical services division, which performs product support analysis to document the design basis, develops technical manuals and creates training course curriculum, all from customer engineering. DTB has three unique divisions with services that complement the engineering product lifecycle from initial design concept to final product. Furthermore, the DTB team has subject matter experts on testing, technical manuals and mobile SCIFs, allowing customers to focus on their core products while the company fulfills the supporting requirements as trusted advisors.
“We want to be the best and that comes from listening to the customer – the voice of the customer is very important to us,” adds Matt. “Quality is equally as important. We never waiver from delivering services of the highest quality and we run 24 hours a day. Our report turnaround times and delivery times are the fastest in the industry. We will move mountains for our customers because they mean everything to us.”
Jim closes: “We strive to be the company customers turn to when the mission is critical and the stakes are highest. Being at the center of complex, high-impact challenges is what drives us as an organization. Our 75 years of success are built on the dedication of our employees, the trust of our customers and the strength of our partnerships. We deeply value their commitment, work ethic and passion, which continue to define who we are. I feel incredibly fortunate to be part of an environment built on that foundation.”
