Physical Optics Corporation — Department of Defense SBIR Phase I: MDA16-015

Description

To address the MDA need for a repeatable manufacturing process for aerospace-grade aluminum alloy propellant tanks, Physical Optics Corporation (POC) proposes to develop the new Robotic Bonding (ROBOBOND) system, which combines both rotary friction welding and friction stir welding in an entirely self-contained device with semiautomated operation (fully automated in Phase II and beyond). The ROBOBOND system integrates novel fixturing and automated computer numeric control (CNC) technology to provide automated assembly of aerospace-grade aluminum tank segments. In Phase I, POC will define the variables for repeatable tank manufacturing, resulting in a technology readiness level (TRL)-3/-4 benchtop demonstration prototype. In Phase II, a ruggedized prototype will be demonstrated to show ROBOBONDs capability to repeatedly join realistic test coupons with accuracy to within 0.76 mm (~1/30th of an inch) with minimal to no postprocess machining for the finished part in an environment representative of existing MDA-sponsored assembly lines and setups, to yield a TRL-5/-6 demonstration prototype. Approved for Public Release | 16-MDA-8917 (15 November 16)