Systems engineer Robert Petterborg, from Sandia National Laboratories, took on the challenge of designing a new cable connector to improve testing of the W80-4 weapons system. Petterborg, who voluntarily undertook the project, emphasized the importance of innovation, stating, "If everyone did things the way we've always done them, we wouldn't have innovation."

Utilizing 3D printing, Petterborg designed the connector, which he estimates would have taken a dedicated team three to five years to develop without this technology. The new connector aims to enhance reliability and confidence in the stockpile by eliminating bad connections and reducing the need for retests at Pantex Plant.

Human factors engineer Michelle Pang collaborated with Petterborg on the project, gathering user feedback to create a more user-friendly connector. The new design features a transparent window for visual alignment, simplifying the connection process and reducing the risk of damage to cables.

The production technicians at Pantex provided positive feedback on the ease of use of the newly designed connector, highlighting its efficiency in testing weapons systems. Rapid Development Connector teams at Sandia played a crucial role in fabricating multiple design iterations quickly, saving time and costs.

Petterborg credited the expertise and collaboration at Sandia for the project's success, stating, "At Sandia, we have one of the greatest, deepest knowledge bases of any place in the world." The achievement of designing the new connector has garnered attention, with Deputy Labs Director Laura McGill showcasing the assembly to congressional staff members.