Keystone Synergistic Enterprises, LLC — Department of Defense SBIR Phase I: J201-CSO1

Description

There is a clear and pressing need to integrate advanced digital technologies for repair and sustainment of aero-engine components.  Commercially available (MRL 10) structured-light scanning nearly meets the challenge by easily achieving metrology-grade measurements (3 microns) for almost the whole part, failing to meet the accuracy for sharp edges.  Sharp edges are high-damage features and the lack of accuracy hinders the adoption into aero-engine maintenance, repair, and overhaul (MRO).   Keystone solves the edge accuracy and preserves the cost-effective benefits of whole-field digital scanning by integrating a laser profiler (another commercially available MRL 10 technology) with the structured-light technology.   By uniquely combining the two technologies into one process we achieved metrology-grade measurements of the whole part, including (0.5 micron) of the metal edge.  The Keystone whole-field digital inspection technology doubles operator productivity with 2.5X accuracy and provides key data to support digital engineering analysis.  With Keystone’s whole-field scans and enhanced edge precision the MRO can: Digitally baseline the “as-used” products Conduct in-process and final repair inspections using one tool instead of 100s Apply data to CAD inspection, MRB disposition, select optimal repair method, and engineering analysis  Commercialization includes integration into the OC-ALC by launching within the 76th PMXG, other Aor Force ALC’s followed by DoD and commercial end users.