Tri-agency collaboration printing outside the lines | Transportation Security Administration

Louisiana Lead Explosives Specialist and Innovation Officer Mike Nelson’s invention puts new field explosive screening kits at the tips of officers’ fingers. The unassuming holder neatly organizes and conveniently dispenses supply kits used in the screening protocol for explosive trace detection (ETD) at the checkpoint.The need was basic, but the simple product projected a polished, professional checkpoint image while making security operations more efficient and faster – an example of sweating the small stuff to the benefit of officers and passengers.

“The dispensers are designed to mount inside the ETD cabinets, but they can be installed anywhere,” said Nelson.While necessity might have been the mother of Nelson’s invention, the Lift program under the TSA Chief Innovation Office provided the collaborative spark that made the project tangible. The wildly successful Lift Cell program uses people, partnerships and technology to solve the most basic problems, but without 3D-printing resources, some dreams die on the computer screen.

“TSA does not currently have a robust 3D-printing capability,” said Innovation Program Manager Vanessa Couch. “By partnering with other agency partners, we can use their 3D-print labs as well as experts who can design products for use by our employees. We can also learn from our partners how to 3D print, so when we do get the capability, we will be a step ahead of the curve.” Recognizing the benefits of collaboration, the Chief Innovation Office hosted a two-day Trilateral Innovation Summit with representatives from TSA, U.S. Air Force and U.S. Coast Guard innovation groups to learn about each other’s programs and explore shareable resources, mutual challenges and possible solutions. “TSA is not alone in our endeavor to innovate, and we are not alone in our desire to improve the workplace for our employees and improve the security and experience for our passengers,” said Couch.

“Our goal was to have two workable solutions that could be adapted further as necessary for TSA use,” said Coast Guard Chief Petty Officer Jonathan Zlocki.Louisiana Explosives Specialist and Innovation Officer Andrew Allen credits Zlocki, the head of his department’s 3D-printing facility, with helping provide the products for the TSA checkpoints. The Coast Guard provided their expertise and equipment to help produce Nelson’s design. They’re currently installed at Louis Armstrong New Orleans International Airport (MSY) and other checkpoints across the country.The second deliverable was a 3D-printed wand used in explosives detection screening. Nelson said the prototype originally called for just two replacement pieces to be printed. “However, the project quickly evolved into a complete overhaul of the entire unit, because many of the parts aren’t designed to last (given the high repetitive use),” explained Nelson. “At a savings of $462 per ETD wand, the 3D-printed version is more efficient and economical,” said MSY Federal Security Director Arden Hudson. “That is a huge cost saving when the material to print is $10 per printed wand, and we have 32 ETDs.”

“Zlocki, out of (Coast Guard) Base New Orleans has been such a tremendous help and has gone above and beyond in assisting screening ops in designing and printing our items,” said a grateful Allen. Besides Hudson’s involvement, Nelson also tipped his hat to Assistant Federal Security Director Randell Lundsgaard and Deputy Assistant Federal Security Director Brad Meyer for their continued support, funding and encouragement. The Innovation Office continues to pioneer ways to work smarter. “We are also looking into opportunities for our employees to be able to attend training events put on by the other agencies that would not typically be available to our employees,” said Couch. “By working with our government partners, we can identify shared problems and see how the other agencies have solved these problems. Why reinvent the wheel when someone else has already solved the problem? The more we talk with the Air Force and Coast Guard the more common problems we identify.” By Karen Robicheaux, TSA Strategic Communications & Public Affairs