The military purchasing community has traditionally enjoyed the unusual luxury of being able to specify vehicles that are, to a substantial degree, ideal for their application. They are designed specifically to excel at their original task, to last a long time and to deliver exactly what it says on the tin. But is this the best solution? Certainly there are many applications where only a bespoke vehicle can deliver the required capability. There are also many applications where standard commercial vehicles can provide most of what is required at a cost so much lower that they can almost be considered disposable. But what of the middle ground?

“The commercial vehicle world is advancing increasingly quickly. This is not the truck industry of ten years ago, or even five years ago,” says Steve Elmes, head of Millbrook’s Special Vehicle Group. “There are many roles for which today’s standard commercial vehicles can be modified to meet all the objectives very cost effectively. MCOTS offer an opportunity to slash the cost of vehicles by three to five times - twice as many vehicles for half the price? It’s too good an opportunity to ignore.”

The fundamental requirement for making MCOTS successful is to start with a rigorously defined requirement. “Civilian vehicle manufacturers spend a lot of time understanding what their customers want and how they use their vehicles,” continues Elmes. “This allows them to perfectly match that need whilst not spending money on anything that doesn’t add value. That’s what we are trying to achieve with MCOTS.”

The starting point for an MCOTS programme, though, is very different to that for a bespoke military vehicle programme, which traditionally over-engineers because the operating conditions can never be defined in advance. It is very hard to predict where field operations may be required.

“This type of flexibility is useful but immensely costly,” says Elmes. “There are many categories of vehicles that do not need this breadth of ability, particularly when their low cost means they do not have to endure many decades of service. With careful planning of the vehicle fleet and its re-rolling capability, the MoD is finding significant areas where more focussed abilities are just as acceptable.”

Having defined the precise operating requirement, the next stage is to evaluate possible commercial off-the shelf vehicles and the degree and type of modifications required. Millbrook’s extensive off-road facility, which can simulate almost any world terrain, is a vital part of providing this understanding. Their laboratories offer the same level of detailed understanding for other areas of the vehicle.

“Areas that typically need upgrading include electrical systems, engine cooling systems and air filtration. We may also have to strengthen the suspension and modify the chassis and body to accommodate specific loads and terrains,” says Elmes. “Understanding the specific interactions is a critical part of delivering a durable and effective solution with the required functionality.”

Elmes sites examples such as different wear patterns on the seats as personnel enter vehicle cabs and the need for engines to run on a range of fuels. Millbrook’s laboratories can analyse everything from light bulbs to an entire vehicle, simulating its actual, in-field usage and identifying areas that need to be strengthened or otherwise improved. Most tests also simulate the climate of the mission and can include rain, salt, baking sun and even the right type of grit for the target terrain.