Pull and Stick Nutplate Process

To address the Air Force"s need for a nutplate installation process that requires no preparation of the nutplate before installation, Physical Optics Corporation (POC) proposes to develop a new Pull and Stick Nutplate (PASN) process based on implementing an innovative micro-channel passive fluid mixing geometry that is operator-independent and cost-effective on top of existing and proven packaging processes. This innovative design uses one simple, inexpensive adhesive sachet instead of the bulky adhesive cartridge, dispenser, and mixing tip that are currently used. PASN utilizes an adhesive injector guide that mitigates the risk of creating foreign object debris (FOD), which requires hole reaming. Because PASN is compatible with the current approach of individually placing nutplates in a nitrogen-filled bag, it directly addresses the Air Force"s requirements. In Phase I, POC will demonstrate the feasibility of PASN by developing a prototype nutplate/adhesive combination and testing it in a laboratory to ensure equal or better performance compared with the current solution. A preliminary cost estimate and transition plan will also be proposed during this phase. In Phase II, POC plans to further mature the design and demonstrate the process in a representative production environment with a detailed cost comparison and transition plan. BENEFIT: Military applications of the Pull and Stick Nutplate (PASN) process will be relevant for both vehicular and structural platforms that require adhesive nutplate installation. The process can be incorporated by the Air Force into installation processes involving aircraft such as the F22 and F35. Commercial applications of 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 both single and multiple part adhesives and can also be applied universally to adhesion processes that require adhesive dispensers.