JLTV Case Study


The JLTV program incorporates lessons learned from the earlier and now halted Future Tactical Truck Systems (FTTS) program and other associated efforts.[4] The JLTV program has evolved considerably throughout various development phases and milestones including required numbers and pricing. Variants are capable of performing armament carrier, utility, command and control (shelter), ambulance, reconnaissance and a variety of other tactical and logistic support roles. JLTV follows the US Army’s Long Term Armor Strategy (LTAS) with kits for two levels of armor protection


GLSV developed a new muffler to improve the exhaust system.

The newly developed muffler improves the acoustic performance of the exhaust system, and addresses needs to improve the acoustic performance of the vehicle.

Problem / request

From National Defense Magazine article, 10/15/2019:

“Oshkosh Defense has begun upgrading the joint light tactical vehicle in response to a critical Pentagon report issued earlier this year, a company executive said Oct. 15.

Bigger windows, a front-facing camera and a muffler, George Mansfield, vice president and general manager of joint programs at Oshkosh Defense, said in an interview at the Association of the United States Army annual meeting in Washington, D.C.”


GLSV worked with Oshkosh Defense to develop a new exhaust muffler, taking it from initial concept to a fully operating production line in 8 months.

Technical Approach

GLSV’s typical exhaust development cycle is executed to meet stringent requirements for performance, durability, space claim, and manufacturability. We begin with a concept design that is specific to the vehicle and engine we are designing for. We mature and optimize the concept through virtual prototypes, in which we build simulation models to predict and optimize the acoustic, flow, and thermal performance. 

In addition to optimizing the performance, the simulation models are used to verify the robustness and durability of the exhaust system by simulating real-world operating conditions and environments.

Our detailed design phase ensures that the exhaust system is optimized for manufacturing and assembly considerations. Our initial prototype build is used to close the loop with our virtual prototype, by conducting performance and durability tests to validate the performance predicted by our simulation models.

Once we have proved out the design, we begin our rigorous process to release the exhaust for production. We finalize our manufacturing process flow, and design and build tooling and fixtures for sheet metal forming, welding, machining, and inspection. Weld qualifications, quality plans, and inspection requirements are finalized, all with the goal and intention of manufacturing a product with repeatable, consistent, high quality.