SBIR-STTR Award

Using appliqu‚s to replace paint requires a "total appliqu‚ process solution" in the form of an "Applique Process Cell": an integrated set of technologies and methods which address ALL of the process requirements so as to utilize appliqu‚s efficiently, especially reducing trimming requirements when covering complex curved surfaces. The required enabling technologies for an Appliqu‚ Process Cell currently exist in mature forms in disparate applications and locations. Assembly Guidance.has developed several of these enabling technologies and has established relationships with companies which can provide all of the other hardware and software components. The proposed team includes Lockheed Martin, 3M, a US Air mechanic familiar with appliqu‚s, a metrologist experienced in capturing aircraft surfaces, a CAD engineer specializing in cutting and applying material to aircraft surfaces, a high accuracy material cutting specialist, and a Principal Investigator experienced in quality process development in manual placement of sticky material on complex surfaces, kitting and process-guiding displays (a Tibbetts Award Winner). This team will test, document, and refine the "total applique process" in the area of repeatable application on complex curves with reduced trimming. The result will be descriptions of the methods, technologies, costs and benefits for addressing complex surfaces with Applique Process Cells.

Benefits:
lower costs in installing appliqu‚s, lower costs/improved performance in aircraft finishing, significant reduction in environmental impact in aircraft finishing stripping\.

Applications:
All Military and Civilian Aircraft, Maritime

Realization of the benefits of appliqu material as a replacement for paint on large, complex aircraft structures requires a significant improvement in process cost, material utilization and cosmetic quality. The ability to achieve improvements in process cost/quality has been successfully demonstrated, on a small scale, but involving ALL processes, within SBIR Phase I. Optimization of an integrated suite of digital tools improves process planning, material cutting, sorting and application. All components of this digital appliqu processing will be integrated and operated for refinement on full size aircraft structures (F-16/F-35), by shop personnel, at Lockheed Martin. The proposed appliqu cell includes: automatic capture and digital modeling of aircraft surfaces for applications where accurate CAD surface definitions are not available, rule based definition of ply size and shape optimized for layup operators and surface characteristics (top, side, bottom, steep curve, etc.), flat patterning material for automatic, high speed cutting with consideration for material drape and stretch characteristics (reducing/eliminating manual trimming on aircraft), nesting for maximum material utilization, digitally controlled kit sequencing and labeling for accurately ordered kits and maximum cutter throughput, and laser pattern projection for precise manual placement and optimal cosmetics (.100? total process accuracy anticipated) on complex aircraft structures.

Keywords:
applique, placement, laser projection, nesting, sorting, surface creation, labeling