Efficient Removal of In-Service Low Observable Materials via Controlled Spot Media Blasting

Perfect Point designed, manufactured, and markets a self-contained spot media blaster (S-Blaster) that has been commercially available since 2014.  This device is used to remove typical aerospace grade coatings and materials from fastener heads to allow for ease of removal, damage mitigation from abrasive tools, and efficiency of process.  While the current model performs effectively when used on general aircraft coatings and fillers, a capability gap was discovered when evaluated against 5th Generation Low Observable coatings and fillers, specifically on the F-22 Program.  Due to their unique compositions, the current iteration of the S-Blaster is not capable of meeting mission requirements for effective adoption at scale.   Previous evaluation projects of this technology initially appeared favorable, however field testing proved inefficient at removing these coatings on the deployed weapons system.  The F-22 program has identified Spot Media Blasting as a capable technology to assist in the reworking and repair of these highly-specialized coatings and has a current Defense Mission Need Statement.   The purpose of this development project is based on findings from deployed S-Blaster systems used for F-22 maintenance and it has been discovered that a need for system enhancements are required to meet productivity goals for this Air Force application.  Project Objective(s) will be to remove Low Observable (LO) filler and coatings from countersunk recesses formed above countersunk fasteners and tool recesses formed in certain fastener heads.  This objective will be accomplished by a series of controlled studies to determine the best methods, components, and materials required to meet program guidelines.  Testing and development work will also be performed to prove damage is not being caused to the underlying material and that Material Removal Rates (MRR) meets program maintenance time requirements. In collaboration with the empowered customer, end-user and technology stakeholders, performance results and componentry updates will be captured, measured, and communicated for optimal outcome.  Following the conclusion of this project, improvements to the S-Blaster product and process will be beneficial for any other Program or Weapon System in the inventory.