Physical Optics Corporation — Department of Defense SBIR Phase I: ABSTRACT: To address the Air Force"s need for a portable integrated drilling and fas

Description

ABSTRACT: To address the Air Force"s need for a portable integrated drilling and fastening system, Physical Optics Corporation (POC) proposes to develop a new Portable Fastener Installation Device (PFID). This proposed device is based on a new integrated clamping and drilling tool design that will enable the device to clamp multiple sheet metal layers, drill holes to the specified tolerance without de-stacking metallic stack-ups, apply sealant, insert both standard and interference-fit fasteners, and measure the applied torque of an installed nut. As a result, this device offers the ability to combine multiple processes into a single setup, greatly improving manufacturing process time, eliminating the current need for disassembly and deburring processes, reducing operator error, and increasing safety, which directly address the Air Force"s requirements to address current quality and labor concerns on C-130J aircraft production and repair. In Phase I, POC will demonstrate the feasibility of individual components of PFID by testing their functionality individually in manufacturing simulated scenarios. In Phase II, POC plans to integrate all functionality into a single, lightweight, robust tool as well as explore tool modifications required for rivet installation and measurement. BENEFIT: The proposed PFID system will meet the needs of the Air Force by greatly reducing both the labor required to install fasteners as well as ensure quality and consistency while reducing production costs of the C-130. PFID will also prove valuable while performing repairs and maintenance on legacy C-130J aircraft. It will ensure that the Air Force"s aircraft fleet will be produced efficiently, spend as much time as possible in service, and have reduced maintenance time and costs. Furthermore, PFID can be adapted to reduce costs and improve quality for other manufacturers in both the commercial and defense aircraft markets, as well as be adapted to markets with similar manufacturing methodologies, such as those in the automotive and ship building industries.