Robotic Adaptive Sanding System (RASS)

The proposed effort will develop and demonstrate a Robotic Adaptive Scuff Sanding System (RASS) to automate surface preparation for coating refresh on the F-35 airframe. Manual sanding of low observable (LO) coatings is a labor-intensive, ergonomically challenging process that demands extreme precision (0.002–0.003” material removal) across complex geometries. The RASS solution aims to reduce process variability, operator burden, and total turnaround time (TAT) by introducing an intelligent, automated alternative.RASS integrates several key innovations:Adaptive force-controlled sanding using an active compliance tool to maintain precise contact pressure across varying surfaces.Real-time thickness measurement via Terahertz sensing to identify out-of-spec regions and dynamically guide sanding parameters.Multi-head sanding tooling for large-area coverage with servo-driven control.Automated sandpaper change and verification for fully unattended operation.These technologies are already in use or under validation in production environments for other DoD platforms. This Phase II effort will combine them into a unified, production-representative solution tailored for the F-35 sustainment environment. Testing will be performed on representative geometries, followed by a system demonstration to validate sanding performance, repeatability, and operational readiness.The RASS system directly supports Air Force goals for improved depot efficiency, reduced rework, and long-term sustainment cost savings. Beyond the F-35, the system has commercialization potential across fighter, bomber, and unmanned systems requiring precision LO coating maintenance.