Abstract: A system and a method for securing a panel insert to a panel include a main housing, a heater within the main housing, a coupling rod extending from the main housing, and a clamp assembly coupled to the coupling rod. The clamp assembly is configured to clamp the panel insert to the panel. The heater is configured to cure an adhesive applied to the panel insert to bond the panel insert to the panel.

Abstract: A system for removing a panel insert from a panel includes a main housing. A loading cap is coupled to the main housing. A tension knob is coupled to the main housing. The tension knob is configured to couple to a puller rod. A tension spring is within the main housing. The loading cap is configured to set the tension spring at an initial tension. The tension knob is configured to set the tension spring at a subsequent tension. A heater is configured to apply heat to the panel insert.

Abstract: Methods, apparatus, systems and articles of manufacture are disclosed to prepare an aircraft surface, including depositing a first solution on a substrate on the aircraft surface, the substrate having a first charge, the first solution having a second charge opposite the first charge, the first solution including a carrier fluid, removing a first amount of the first solution deposited on the substrate to form a first layer on the substrate, depositing a second solution on the first layer, the second solution having the first charge, the second solution including the carrier fluid, and removing a second amount of the second solution deposited on the first layer to form a second layer on the first layer to prepare the aircraft surface.

Abstract: There is provided an automated removal apparatus for selectively removing one or more trimmed portions of a laminated ply in a ply-by-ply fabrication process. The automated removal apparatus includes a rotatable reel having a plurality of retractable vacuum panels attached around the rotatable reel. Each retractable vacuum panel has one or more retractable vacuum pad assemblies, and each retractable vacuum pad assembly has a vacuum pad with a vacuum port and a self-sealing valve. The automated removal apparatus further includes actuator assemblies attached to the plurality of retractable vacuum panels, friction reducing elements attached around the rotatable reel, a drive assembly attached to the rotatable reel, and a pneumatic system attached to the rotatable reel and including a valve manifold operable to control an air flow to the actuator assemblies and to one or more vacuum generators to generate a vacuum flow.

Abstract: A method of assembly of a carbon fiber space frame structure eliminates the need for gusset plates at the joints of the space frame structure. The elimination of the gusset plates at the joints of the space frame structure reduces the weight of the space frame structure and eliminates stresses that occur at the joints due to gusset plates attached at the joints.

Abstract: Embodiments described herein utilize Non-Destructive Inspection (NDI) scan data obtained during a process performed on a surface of a structure to update a location of an NDI scanner on the surface. A subsurface feature within the structure is detected based on the NDI scan data, which are correlated with pre-defined position data for the subsurface feature. A measured location of the NDI scanner on the surface is corrected based on the pre-defined position data for the subsurface feature.

Abstract: Systems and methods are provided for splicing airframe components. One embodiment is a method for assembling an airframe of an aircraft. The method includes forming a first skin of a first circumferential section of fuselage, the first skin including a distal portion comprising a lip and a shoulder, aligning a second skin of a second circumferential section of fuselage with the shoulder such that the lip overlaps the second skin, and affixing the first skin and the second skin together via a circumferential splice.

Abstract: Ergonomics improvement systems having wearable sensors and related methods. An example ergonomics improvement system includes an encoder system to couple to a limb of a body. The encoder sensor system to generate first outputs in response to movement of the limb relative to the body to determine a position of the limb relative to the body. The system includes a load sensor to generate a second output representative of a load carried by the body and a position sensor to generate a third output representative of a position of a right foot of the body relative to a position of a left foot of the body.

Abstract: This invention generally relates to the field of nonferrous metallurgy, namely to titanium alloy materials with specified mechanical properties for manufacturing the aircraft fasteners. A stock for high strength fastener is manufactured from wrought titanium alloy containing, in weight percentages, 5.5 to 6.5 Al, 3.0 to 4.5 V, 1.0 to 2.0 Mo, 0.3 to 1.5 Fe, 0.3 to 1.5 Cr, 0.05 to 0.5 Zr, 0.15 to 0.3 O, 0.05 max. N, 0.08 max. C, 0.25 max. Si, balance titanium and inevitable impurities, having the value of aluminum structural equivalent [Al] eq in the range of 7.5 to 9.5, and the value of molybdenum structural equivalent [Mo] eq in the range of 6.0 to 8.5, where the equivalents are defined by the following equations: [Al] eq=[Al]+[O]×10+[Zr]/6; [Mo] eq=[Mo]+[V]/1.5+[Cr]×1.25+[Fe]×2.5.

Abstract: Thermal control system for aircraft main landing gear wheel wells and related methods are disclosed. An example thermal control system includes a conduit defining a fluid passageway between an inlet and an outlet. The inlet of the conduit positioned in fluid communication with a landing gear wheel well and the outlet of the conduit positioned in fluid communication with the atmosphere. The conduit generates a pressure differential through the fluid passageway between the inlet and the outlet to exhaust heat from the landing gear wheel well to the atmosphere.

Abstract: A titanium alloy for additive manufacturing that includes 5.5 to 6.5 wt % aluminum (Al); 3.0 to 4.5 wt % vanadium (V); 1.0 to 2.0 wt % molybdenum (Mo); 0.3 to 1.5 wt % iron (Fe); 0.3 to 1.5 wt % chromium (Cr); 0.05 to 0.5 wt % zirconium (Zr); 0.2 to 0.3 wt % oxygen (O); maximum of 0.05 wt % nitrogen (N); maximum of 0.08 wt % carbon (C); maximum of 0.25 wt % silicon (Si); and balance titanium, wherein a value of an aluminum structural equivalent [Al]eq ranges from 7.5 to 9.5 wt %, and is defined by the following equation: [Al]eq=[Al]+[O]×10+[Zr]/6, and wherein a value of a molybdenum structural equivalent [Mo]eq ranges from 6.0 to 8.5 wt %, and is defined by the following equation: [Mo]eq=[Mo]+[V]/1.5+[Cr]×1.25+[Fe]×2.5.

Abstract: A retroreflective sign comprising a rigid substrate with a pattern of cell walls formed of a polyurethane adhesive or two-part polyurea adhesive, and a polymeric sheet having a front face and a rear face, the rear face facing the substrate, the rear face comprising microprismatic reflective elements is disclosed. The polymeric sheet is adhered directly to the cell walls formed of the polyurethane adhesive or two-part polyurea adhesive while leaving an air gap between the microprismatic retroreflective elements and the rigid substrate in the cells. A method of making the retroreflective sign includes applying a polyurethane adhesive or two-part polyurea adhesive to a front side of a rigid substrate in a pattern defining cell walls; and prior to full curing of the polyurethane adhesive, laminating the front side of the rigid substrate a rear side of a polymeric sheet via the cell walls, the polymeric sheet comprising microprismatic elements.

Abstract: A communication system includes a traffic relay (TR) device for locating unmanned traffic in a controlled airspace. The TR device comprises one or more processors configured to perform the step of receive a status message from an unmanned aerial vehicle (UAV). The status message provides identification and location information of the UAV. The one or more processors are also configured to perform the step of generate a warning message for communication to at least one manned aerial vehicle (MAV) or a manned traffic manager (MTM) device that is communicatively connected to the at least one MAV. The warning message is based on a comparison of the location of the UAV to a designated airspace.

Abstract: Certain aspects of the present disclosure provide techniques for manipulating and securing containers. In one example, a method includes attaching a tool to a first corner fitting of a first container and a second corner fitting of a second container; applying a torque to the rotatable pinion in order to cause the first corner fitting to engage the second corner fitting; and removing the tool from the first corner fitting and the second corner fitting.

Abstract: A method of injecting potting material into at least a portion of a workpiece, comprises positioning a potting press, containing the potting material, over a target area of the workpiece. The target area contains openings, passing entirely through the workpiece. Simultaneously with positioning the potting press over the target area of the workpiece, the potting material is injected into each one of the openings within the target area.

Abstract: Systems and methods are provided for inspection. One embodiment is a method for measuring a hole. The method includes driving a fiber optic probe into the hole, determining a profile by scanning the hole via the fiber optic probe, and determining whether an interface gap exists at the hole based on the profile.

Abstract: Systems and methods are provided for installing ribs and/or spars to a wing panel while a contour is enforced. Methods include suspending a wing panel beneath a shuttle that enforces the contour, advancing the wing panel through work stations via the shuttle, and installing a rib or a spar (or another wing panel) at a work station, while the contour is enforced. Other methods include locating a wing panel beneath a shuttle, coupling adjustable-length pogos to the wing panel at locations distinct from those corresponding with an installation location, e.g. for a rib or a spar, and controlling the length of the pogos to enforce a contour to the wing panel. Some systems include a track, work stations disposed along the track, and a shuttle to advance along the track and convey a wing panel to each of the work stations while enforcing a contour onto the wing panel.

Abstract: A manufacturing system includes a cutting machine, an adhesion machine, and a pick-and-place system. The cutting machine sequentially cuts a continuous length of a unidirectional prepreg into prepreg segments. Each prepreg segment has an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The adhesion machine has a conveyor belt and an adhesion station. The pick-and-place system sequentially picks up the prepreg segments from the cutting machine, and places the prepreg segments in end-to-end relation on the conveyor belt, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. The conveyor belt feeds the prepreg segments to the adhesion station. The adhesion station adheres the prepreg segments to a continuous length of a backing material, thereby resulting in a continuous length of a backed cross-ply prepreg.