Novel and Automated Installation Methods for Aircraft Appliqu¿

Appliqu¿ has demonstrated the potential to save literally billions of dollars in life cycle cost for DOD aircraft as paint replacement, yet very little work has been done to overcome the largest impediment to its adoption; that is, high installed cost. Themajority of this cost arises from installation labor, yet appliqu¿ installation to date has remained almost exclusively a skilled manual operation. Under this program, KaZaK shall develop innovative automated equipment and procedures to address the majorinstallation cost drivers - compound curvature, edge sealing, large area application and protruding head fasteners. Specific concepts to address each of these problems are discussed herein. Furthermore, KaZaK has formed a world-class team to address thischallenge comprised of the appliqu¿ producer, two airframe prime users and an experienced appliqu¿ installation firm in the bus market to consult on best commercial practices.We anticipate that at the conclusion Phase I, the technology developed will makesubstantial progress toward increasing appliqu¿ installation rates from roughly 5 square feet per labor-hour achieved on current aircraft programs to rates of 75 square feet per labor-hour routinely achieved in the commercial