Early in my career I worked on several DoD projects. Some were cutting edge (or bleeding edge). We NEVER EVER went ahead into production without a proof-of-concept first. First, we start with a theory. Then possibly a mathematical model. We had long theorized that there was no atmosphere between the earth and the moon…long before the first plane or even balloon. As technology developed, we were able to test those theories. Scientists had the calculations of the amount of force on a door filled with air in a vacuum decades before the first space flight. There are some unknowns, but much of it was known either with previous testing or with mathematical models. Computers have been extremely helpful in creating models in real-time based mathematical models that are extremely accurate. The math models were designed form previous testing. Sometimes we don’t have a life model to rely on. The Atom bomb is a great example. One theory that was that the A-Bomb could create a never-ending chain reaction that could destroy the earth. The mathematical models showed there was an extremely low probability, but that it wasn’t zero.
Engineers first have an assumption (Idea). Then they test that assumption or parts of their assumption. Many times they have to invent new technology to actually test their hypothesis. Sometimes they don’t have the knowledge or technology to finish what they started so the next generation picks up where they left off.
Politics (either government or business) can be a hindrance or very helpful. Unfortunately, that’s where the money is. And for that money they want accountability. There is probably 3-5 times the amount of documentation in any DoD project I worked on compared to the same type of work in private industry. The DoD also has technical companies that they use as a watchdog and auditor. This accountability can get in the way too. I personally know of $10,000 the government spent on an ashtray. I was working on a radar system for the Airforce. And when the system was complete the Airforce came back with an update to put ashtrays in each of the radar consoles. This meant redoing all the console designs and then all the blueprints had to be redrawn, and refiled and reviewed and approved. At least 20 people had their hand in this for hundreds of hours of work. It was also at this time when smoking was being banned in government buildings. So, the radar consoles were redesigned and built with an integrated ashtray and never used.