Interpolated Liquid Shim Application System

ABSTRACT: To address the Air Force need for a liquid shim application system for automated advanced fighter assembly, Physical Optics Corporation (POC) developed the Interpolated Liquid Shim Application System (ILSAS), which has demonstrated the ability to apply highly precise amounts of liquid shim that achieve perfect squeeze-out of cured material. Studies with the system demonstrate a 300% reduction in material use, a 450% reduction in touch labor, a 450% increase in production speed, improved uniformity by the virtual elimination of the possibility of trapped voids, and reduction of operator variability through automation, compared with the current process. A cost savings analysis projected a $5.7M savings for liquid shim application on the advanced fighter alone, with larger savings projected for masking, post-cure machining, and extension of the system to gap fill, fuel tank sealant application, and hard shim forming. The fully developed Phase II ILSAS, which POC plans to integrate into Northrop Grummans (NGCs) integrated assembly line (IAL), will be an affordable, production-ready, automatic system that will dramatically reduce cost, increase the rate of production, and improve product quality. BENEFIT: Testing of the ILSAS has demonstrated a 300% reduction in material use, a 450% reduction in touch labor, a 450% increase in production speed, improved uniformity by the virtual elimination of the possibility of trapped voids, and reduction of operator variability through automation, compared with the current process. A cost savings analysis projected a $5.7M savings for liquid shim application on the advanced fighter alone, with larger savings projected for masking, postcure machining, and extension of the system to gap fill, fuel tank sealant application, and hard shim forming. Beyond meeting the Air Force manufacturing needs, the ILSAS has the potential to become the new standard in advanced adhesive application.