SBIR Program Makes F-35 Fastener Insertion Cheaper, More Accurate

  • Published
  • By David See
  • Materials and Manufacturing
WRIGHT-PATTERSON AIR FORCE BASE, Ohio --  Researchers from the Air Force Research Laboratory have created an improved projector guidance system in manual cells for fastener insertion during F-35 assembly. The resulting technology could be used at any fastener installation station throughout the F-35 assembly process to standardize data entry processes and to eliminate manual data entry.

The Fastener Insertion Live Link System (FILLS), a Phase III Critical Manufacturing Technology (ManTech) Small Business Innovation Research (SBIR) program, will result in significant recurring cost savings for the F-35. The cumulative unit recurring flyaway (URF) cost savings expected as a result of this effort total $82.9M, and the average time savings per shipset is expected to average 111 hours. The FILLS effort is a good example of a Phase III SBIR in which funding and small-business creativity result in an integrated product that meets Department of Defense needs while facilitating end-user procurement.

Accurate hole location and fastener size information provided by the system reduces kitting preparation and delivery time, reduces fastener installation span time, and assures accuracy. Though the specific database is currently applicable to the F-35 aircraft assembly process, it is expected to find application to other military and industry applications, which will result in reduced manufacturing time and production costs.

Another initial FILLS objective is supporting all current gripping methodologies and establishing a standard for future grip length interfaces. FILLS will be usable at any station throughout the F-35 process to acquire grip length through manual or automated processes. The system will standardize data entry processes to eliminate manual entry.

To date, FILLS has resulted in a central database where each shipset's fastener engineering and as-built-data can be maintained. This includes historical reports on grip length variation and fastener usage, which will lead to process and inventory optimization.

AFRL partnered with Variation Reduction Solutions, Inc. (VRSI) under a SBIR Phase III contract to develop the technology for FILLS. Concurrent with the MRL 4 concept review, VRSI connected with Delta-Sigma Corporation (DSC) to explore and validate their self-funded development of an optical projection system - Projection Works - and a publishing tool called Assembly Works. VRSI subsequently issued a contract to DSC to demonstrate MRL 5, 6 and 7 capabilities specific to FILLS.

Several major project milestones have been achieved since partnering with DSC. By building on commercial off-the-shelf-solutions offered by DSC, project funding that would have supported core development efforts was redirected toward production-ready MRL 7 demonstrations at Lockheed Martin and Northrop Grumman. VRSI and DSC have combined their core competencies to benefit the F-35 program. While VRSI remains the system integrator, DSC continues to improve their Projection Works product to better serve the end users.

Lockheed Martin recently began negotiations with suppliers for 30 FILLS units for the F-35 wing mate and assembly to be delivered to the production floor. Northrop Grumman has decided to assess the optimal implementation sites in the Integrated Assembly Line in order to maximize program return on investment and system use.