Systems & Materials Research Corporation — Department of Defense SBIR Phase I: ABSTRACT: Modern military and commercial aircraft utilize empty areas within the aircraft

Description

ABSTRACT: Modern military and commercial aircraft utilize empty areas within the aircraft structure to store fuel. As such, fasteners and joints within these"wet areas"must be sealed with fuel-resistant sealant to prevent leak paths. Systems and Materials Research Corporation (SMRC) proposes SealKap, a semi-automated intelligent sealant dispensing tool designed to assist technicians with inverted sealing, dome sealing, and fillet sealing over exposed fasteners, nutplates, and fay surfaces, respectively. Currently, fuel resistant sealant is hand applied to wet areas within the F-35 using manual sealant dispensers and spatulas to shape the sealant over the application areas, a time-consuming, operator-dependent process that frequently results in over-application of sealant. This adds unnecessary weight to the aircraft, and its over-use is fundamentally incompatible with the JSF program's ESH mission. Likewise, under-application of sealant can produce detrimental fuel leak paths. SealKap uses custom applicator nozzles and a programmable dispenser valve to deliver a metered amount of sealant to the application area - exactly the right amount and placement every time. Its small form factor and mounted CCD camera assists the technician in difficult-to-access areas of the aircraft. SealKap will benefit the aircraft industry by saving time, weight, and cost all while delivering a higher quality seal. BENEFIT: SMRC's SealKAP semi-automated intelligent fuel-resistant sealant dispensing tool ensures precision application of sealant over exposed fasteners, nutplates, and fay surfaces, improving throughput, quality, and consistency while reducing operator workload and fatigue. SMRC enters into this Phase I program with a clear understanding of sealant dispensing equipment and design of semi-automated handheld tooling for aerospace applications, as well as initial interaction with an established transition partner, SEMCO, the leader in sealant dispensing solutions. With a clear commercialization roadmap entering into Phase I, SealKap has a high probability of transitioning into the commercial marketplace, making it available to aircraft manufacturers and maintainers worldwide.