Pull and Stick Nutplate Process

ABSTRACT: In response to the Air Force need for a nutplate installation process that requires no preparation of the nutplate before installation, Physical Optics Corporation (POC) has developed a new Pull and Stick Nutplate Process (PASN) based on an innovative micro-fluid mixing of two-part adhesive and operator-independent cost-effective dispensing of the adhesive on the nutplate base. The PASN tool uses a sachet with predefined amount of adhesive and an injector guide to mitigate the risk of foreign object debris. The PASN tool is compatible with the current approach of placing nutplates in a nitrogen-filled bag for use without further preparation, directly addressing the Air Force"s requirements. In Phase I, POC successfully demonstrated PASN feasibility through design and fabrication of PASN prototypes and creating a solution plan with cost estimates and a transition plan. The Phase I prototype operates with consistent, premeasured, and prepackaged amount of adhesives and provides uniform dispensing of the adhesive on the nutplate base. In Phase II, POC plans to further test and mature the design and demonstrate the process in a representative production environment with a detailed cost comparison and transition plan. Testing for the adhesive"s strength, shelf life, and other properties will be performed. BENEFIT: Military applications of the Pull and Stick Nutplate (PASN) process will include vehicular and structural platforms that require adhesive nutplate installation. POC has established working contacts with DOD prime aircraft and nutplate manufacturers to help in the transition of the PASN process into the aircraft manufacturing process. The PASN process can be incorporated by the Air Force into installation processes involving modern aircraft. Commercial applications of the PASN process include the transportation industry, where the PASN process can be utilized in the construction of civilian aircraft, sea vessels, and ground transportation. POC"s PASN process can be adapted to accommodate multiple-part adhesives and can also be applied universally to processes that require adhesive dispensers.