Handheld, Snapshot-Based 3D Fastener Inspector

ABSTRACT: Luna proposes to develop a unique, handheld 3D surface inspection tool for accurate measurement of fastener depth and fill flushness on 5th generation fighter jets. This lightweight 3D"camera"will generate automated, snapshot-based 3D maps of filled and unfilled fasteners on the aircraft"s unfinished surfaces. High-resolution 3D surface data is converted to a reading of flushness and depth for multiple fasteners in a single image, with very little user interaction required. This data provides the technician with a repeatable, near-instant reading on whether or not to re-work the fastener. By enabling rapid, accurate, and repeatible inspection of multiple fasteners in a single snapshot, Luna"s 3D fastener inspector will provide a key capability for technicians on the F-35 flight line during the ramp up to high-rate production. The proposed Phase I effort will focus on demonstrating the feasibility of the technology to meet program goals, with an emphasis on demonstrating accuracy and repeatability, simultaneous inspection of multiple fasteners, and operation in the expected production line lighting environment. Luna intends to leverage its strong existing relationships with prime airframe contractors to help guide the technical effort on a path toward realistic transition and commercialization. BENEFIT: The F-35 has over 40,000 filled fasteners on its outer mold line, each of which must be manually filled and inspected for flushness during production. Reduction in the time required to fill and inspect fasteners is critically required to reduce aircraft build time for future full-rate production. Luna"s handheld 3D fastener inspector is a transformative new tool, capable of making accurate non-contact measurements of flushness and depth on multiple fasteners at once. It will directly reduce the time required to inspect fastenrs; and its imroved accuracy and repeatibility will prevent the need for time-consuming re-checking of flushness measurements. The savings in inspection time is directly scaled by the large number of fasteners on the F-35, providing the Air Force and its commercial parteners with a tremendous return-on-investment for the technology. Furthermore, Luna"s handheld 3D imaging system has the cross-cutting potential to streamline other inspection tasks during F-35 production, such as panel gap/step measurement.