The MCH-100 Battery Powered Heat Gun manufactured by the Malcom Company began development in early 1998. When they accepted the challenge presented by the Aircraft Wiring Support Equipment Commodity group, (AWSEC) at Naval Air Systems Command, NAVAIR, Lakehurst, NJ.

The AWSEC challenge was one of necessity. The modern aircraft is a marvel of electronic controls, weapon systems and devices. As the airframes must be kept in a flight ready state, the service life of an aging airframe is extended by constant upgrade and inspection. The men and women who are charged with the maintenance and upkeep of these systems needed a flameless heat gun tool for wire and harness repair. It had to be quick, portable, lightweight and small enough to be used in the often-cramped conditions within the airframe. Wiring harness repair and replacement, and the continual update of Avionics within the airframe, is an around the clock operation in the Fleet.

The tools that were available required cables and power source hookup to operate. They needed to be near a power supply, or an APU on the flight deck. This resulted in long tangled power cords; bulky equipment in the repair area, and frustrating time delays while all of this was brought to the job site. The call went out from AWSEC to the industry to find a better way. Malcom Company heard the call. And they accepted the challenge, against long odds, that a practical solution could be found.

They called on their experience as representatives of the Leister Company, the heat gun manufacturer. They had a clear understanding of the goal. First they determined which heat gun would do the job. Leister made a lightweight heat gun that could be adapted to the design. Then began a search for components to be used for the prototype design.

To meet the first criteria, fast and easy portability, the tool had to be self-contained. No cables or APU connections would be allowed. It had to operate from its internal power. They went on a search for battery power. They determined that they could use standard rechargeable 24V Nickel Metal Hydride. These had been given approvals by the Navy battery facility at Crane, Indianapolis labs and by the U.S. Army. They were readily available, and only needed adaptation for powering the tool. After many trials and test, a solution was discovered. Their design achieved the portability, without external cord or cables.

The tool also needed to be compact and lightweight. This had to be accomplished with a battery package for power and a heat gun for the actual work. The heat gun that they chose has a stand-alone weight of 13 ounces. It can supply up to 1000 degrees Fahrenheit of working temperature. The tool chosen is simple in design, rugged, long lasting and compact.

The tool had to meet the military’s Electro Magnetic Interference criteria. Trial and error, coupled with Yankee ingenuity discovered a way to modify the shielding of the tool to bring it into compliance with the most stringent operating conditions. A successful test was performed and certified.

The tool had to be packaged in a manner that would protect it from salt spray, severe impact or accident. Vendors were sought, prototypes designed and approved for the Navy mission. Flight decks of an operating Carrier are in themselves a hostile environment.

Constant communication with mission officers gained insight and valuable suggestions for modifications. Each element of the design had to conform to the conditions set forth in the proposal. Each challenge was met and overcome. Mission accomplished.

The MCH-100 has been deployed around the fleet. During Iraqi Freedom shipments were made to Army units in the combat area. This tool has come to the attention of military maintenance managers in each service. The tool offers a long MTBF. Full specifications are on the description pages of this site.

This tool can be supplied with a soldering iron, various heating elements, and over 500 nozzles of varied configuration. The tool can be supplied packaged to meet mission requirements.

In any requirement for a fast, efficient harness and cabling repair tool, the MCH-100 fills the need. Military or commercial, remote field location, hostile environment or cramped compartment, the battery operation gets the job done. With many configurations of soldering devices, tips, and accessories, each tool can be packaged for individual requirements. The tool can travel fast, work fast, and gets the job done. We will be happy to provide a demonstration tool for your evaluation.

The MCH-100 is an exclusive offering of the Malcom Company. It is a credit to those who perceived the need, and to those who completed the task. It is testimony to old-fashioned Yankee creativity.

For more information on the MCH-100 and any questions you may have about the tool,please let us know. We will be glad to discuss applications and mission modifications.

Thank you for your interest.
Jonathan Bixby,
Product Manager, for the MCH-100
jonathan [at] malcom.com
Toll Free: 800-289-7505
Outside US: 401-625-5099
Fax: 401-624-3081