The National Nuclear Security Administration (NNSA) approved the first production unit of the replacement fuze in March of this year through their Quality Assurance Inspection Procedure.

“Sandia’s role is to deliver a fuze that meets the Air Force’s requirements. Completing the first production unit is a visible milestone in maintaining a credible deterrent,” said Brad Boswell, a director of Sandia’s nuclear deterrence modernization program.

“It demonstrates that we are providing the necessary capability for the U.S. nuclear deterrent into the future,” he added.

U.S.’ nukes get new fuze

Work on the new fuze began in 2011, with Sandia given the task of incorporating Air Force requirements into a form, fit, and functional package. The fuze also had to fit into the Mark 21 aeroshell, Minuteman III missiles, and W87-0 warheads.

“The early engineering work takes a lot of time. While some of it is done in parallel, much of the work must be sequential,” said Bob Oetken, a former program manager for the fuze program.

“We’re doing a very specific job that requires, in many cases, custom parts,” he added.

Sandia explains Pre-production testing of the fuze included analysis through testing and other engineering tools to ensure the fuze would function as intended.

“Qualification involves significant resources and time. We are in a very rigorous business. Some of the qualifications are used to verify that we are meeting requirements and take as long as three years from concept to delivery,” Oetken added.

To this end, the new fuze underwent various tests, including environmental, ground, and flight tests, to ensure its strength, durability, and endurance during missile launch and ballistic reentry. With the fuze now in full production, Sandia’s role will now be changed.

Sandia’s role will now change

“As the design agency, Sandia is responsible for the component until the weapon is retired. Sandia is accountable for ensuring that the weapon with the fuze attached is safe, secure, and reliable,” Boswell said.

As part of the stockpile assessment, Sandia will use modeling and simulation, as well as flight and ground testing, to ensure that the fuze continues to function as intended. The fuze will now enter full production.

“This first production unit marks a significant milestone not just for Sandia but the broader nuclear security enterprise, particularly our partners at the Kansas City National Security Campus,” Boswell said.

“While we stop to recognize this achievement, we must also acknowledge this is the start of the next phase of our partnership as we work to meet key production milestones to deliver the [number] of fuzes needed to meet the needs of the stockpile,” he added.