Aircraft repair and sustainment presents unique challenges to the Air Force that can be resolved with the assistance of Additive Manufacturing (AM) technologies. Bullet holes through an F-16 vertical tail skin forced Ogden Air Logistics Complex (OO-ALC) to disassemble the entire tail assembly for repair. Due to this disassembly, OO-ALC lacked sufficient datums to: (1) accurately machine the mounting lugs consisting of a 0.001” hole pattern tolerance and (2) properly align the rudder actuation “doghouse” structure to the rest of the tail. Geodetic Systems VSTARS photogrammetry was used in coordination with a Creaform HandySCAN 700 to obtain a digital model of an assembled F-16 vertical tail. This “as-built” master definition was used as a means of digitally aligning the unassembled repair tail to ensure proper orientation. With this digital orientation, the mounting lug hole locations could be determined within the specified hole pattern tolerance. The model was also used to design an additively manufactured fixture used for properly locating the “doghouse” structure.
- Implement advanced digital metrology methodologies to obtain robust solutions to unique and complex problems
- Integrate additive manufacturing to improve traditional processes