Alion’s mSTAR™ Mobile Support Technologies and Repair Modules™ provide rapid fabrication and repair capabilities at the point of need for equipment maintenance as well as the prototyping of unique tools and hardware for unanticipated mission needs. They are easily transported worldwide and to remote locations for military, disaster relief, and support for industrial equipment.

Each module is an 8′ by 8′ unit that can be deployed within minutes; modules expand threefold, using two expandable sides. The modules are self-sustaining, as each has a generator set that runs on JP-8 fuel, with generators that provide electricity for heating and cooling as well as the operation of each module’s various tools.

Although each has a specific primary capability, all of the modules carry a basic set of hand tools and an air compressor. Flexibility is enhanced by the ability to move most tools/work tables outside of the module, where power and air pressure connections are provided. This allows for the fabrication of oversized products or work that produces a large volume of chips/dust to be in an open area.

Available Modules

Base Module SS-1A – A hub for design, fabrication, and repair, this module also provides office and possible living quarters for a 1- or 2-person operational team. Computers are included with 3D CAD (Computer Aided Design) software to enable design. In addition, this module includes a wide array of contractor-grade, large power tools, cordless 18V battery power tools, and hand tools packed within Pelican cases. A full set of woodworking tools is also included as well as tools for electrical/electronic repair and fabrication. In addition to independent operation, this module can be employed in conjunction with the machining or welding modules as a base unit for operating personnel.

Machining Module SS-1B – This module provides fabrication and project workspace support to enable production of a wide variety of parts and assemblies. The heart of this module is a lathe / mill / drill combination machine tool. This flexible tool is hard-mounted to a work bench that is installed in the module. Complementing the metalworking equipment is an extensive set of measuring tools to ensure accurate machined parts. Also included is a basic welding unit, creating a versatile, small-scale “shop in a box.” This module also has the capability for fabric cutting and joining.

Welding Module SS-1C – With a variety of metal welding and cutting technologies, this module supports more extensive metal fabrication and cutting than any of the other modules. It can be used for working on large pieces of equipment and large vehicle repair, as it handles equipment and tools for both sheet metal and composite material fabrication.