The U.S. Navy operates in some of the most demanding environments on Earth, where reliable equipment is essential for mission success. One area of focus has been the Aircraft Elevator (ACE) lock assemblies and stanchion linkage systems found on Navy ships. These systems include U-joints that are regularly exposed to saltwater, weather, and other harsh conditions. To help protect those components and reduce maintenance costs, the Navy partnered with Python, a brand of Suburban Manufacturing Group, to develop a durable, reusable U-joint cover that could be easily installed, removed, and reinstalled during regular service.
The Problem
The Navy previously used single-use dust boots to protect U-joints in elevator and stanchion systems. These boots were often damaged or destroyed during quarterly maintenance and could not be reused. Once removed, they were typically discarded and never replaced. This resulted in essential joints exposed to the marine environment, leading to corrosion, increased maintenance, and shortened equipment life. With no formal process for replacing them and no suitable alternatives available, the Navy needed a more effective solution.
An unprotected U-joint system on a Navy ship is shown with a worn metal dust boot in place. The setup exposes key components to the surrounding marine environment, illustrating the maintenance challenges that led to the development of Python’s reusable cover solution.
The Solution
After identifying the issue, the Navy's NSWCPD 431 Branch worked with Python to design a rugged, reusable U-joint cover that could replace the old dust boots. The project built on an existing relationship that began with the Navy’s use of Suburban’s LubeMinder automatic lubrication systems. Together, the teams developed the SW-1093 cover, a fabric-based solution that protects the joints while allowing for easy removal and reinstallation. Additional part numbers were later created to fit newer, larger U-joint configurations, including SW-3092 and SW-3093. These covers were added to ship installation drawings and have since become a standard option for protecting exposed systems.
The SW-1093 U-joint cover, a flexible, dark-colored fabric assembly, installed on a ship's U-joint. Its rugged design provides protection while allowing for easy maintenance.
The results
Proven Field Performance
The covers have been evaluated and approved for use by TYCOM ship support teams. They hold up well in service, maintain their integrity after multiple uses, and are now routinely reinstalled on Navy vessels.
Lower Maintenance Costs
By replacing single-use boots with a reusable design, the Navy is reducing waste and cutting down on unnecessary repairs caused by environmental exposure.
Simple Implementation
The covers require no special training or procedures to install. Maintenance teams simply clean and regrease the U-joints quarterly, then reapply the covers. They are often installed during standard shipboard modifications or during equipment upgrades.
Scalability and Future Potential
Although developed for ACE stanchion systems, these covers are now being used across multiple ship classes and configurations. Their consistent performance and reusability have led to growing adoption within Navy ship systems where U-joint protection is critical.
Strong Collaboration
The development process was a joint effort between the Navy and Python. The Navy presented the problem, and Python offered a material and design solution that met the technical and logistical needs of the application.
Need a custom textile solution for your toughest applications?
Python’s collaboration with the U.S. Navy is just one example of how we deliver mission critical protection in some of the world’s harshest environments. Our durable, reusable U-joint covers were engineered to meet exact specifications, reduce maintenance time, and extend equipment life.
Whether you're operating in marine, industrial, or off-road environments, our textile team can develop a tailored solution to protect your systems and cut long-term costs.
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