1. AIRTEC Congress 2015 – Call for Abstracts
ADVANCED COMPOSITE TOOLING PROCESS SUPPORT &
UP-STREAM LOGISTICS – When {off-loading} to Suppliers…
How Tooling SOW {Statement of Work Packages} “subject content”
can save countless $ and lower extreme cost on advanced
Composite Aerospace Carbon Fiber Programs.
Small to large volume production support.
Cost effective on 100 million to 1 billion $ + programs.
May 2015 Polar Aero Structures Corp by Daryl Lenhard USA
248-470-3179 polaraero2021@aol.com
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2. Understanding the Tooling “End results” before build…
Doesn’t matter what your building: small - large UAV, Business Jets, Commercial A/C, Fighter A/C, Launch Vehicles for Space, Air
Ship Primary Structures; Military Land or Sea based vehicles – all “Production Activities” seek an acceptable transition to
Replicate Units with limited errors. You can build accuracy into your program “up-front” as well as overlook the minute
details that produce major production errors. These errors are extreme if overlooked. Protect investments - in advance.
Applications support business jets to billon $ air vehicle systems - or master the Tooling on a $200,000 Sports Car build.
The End results are: “Engineering Performance & Quality Acceptance” per the CAD file & Origin of Design Intent. In regards to
Tooling: all programs need to reflect the Geometry of your build & OML {outer mold line} finish of the product – relative to
the internal structure & how those systems are “joined together to manifest a workable product”. All needs to be user
friendly upon production assembly. Proper body line gaps where a visual can detect what is uniform & what is not Up-
stream: Tooling can be Planned to meet allocated Tolerances that complement each & every carbon fiber part.
Stealth Air Vehicles at $1 to $2 Billon per unit “master design protocol” to create the “Stealth Effect”. Without giving away
Secrets …“all builds are about Tolerance” & the +/- factor. Land & Sea based vehicle systems also use this technology.
Engineer’s strive to anticipate a smooth build, if the geometries are specifically called out, where one surface will not encroach
upon another. Theoretical split lines of materials expansion & contraction coefficients must govern Tolerance’s at the
velocities they are intended to endure. This needs to be incorporated into the SOW packages.; to Proof the effectiveness
of proficient & production outcome. All of this needs to be preconceived in not 1 but 3 Statement of Work Packages.
If intention is pre-assembled system components to streamline production schedule, then a 4th SOW is implemented
verifying Statement of Work Packages 1-3. Selecting 4 qualified Michigan Suppliers – secures a repeatable supplier base.
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3. How SOW 1, 2 & 3 - Supports the other…
In Advanced Composite Carbon Fiber Builds – simple mistakes are being made today when selecting Suppliers & lack of enforcement of Material Sciences
behind the build. This can result in hundreds of million of $ in errors on up. When selecting a facility, make sure the elevation will yield proper
vacuum requirements that match Top Tier Epoxy Resin Manufactures Requirements of 25 to 30 “ of Mercury to Compress a part. Mold Tools should
be made in 68 to 74*F with controlled humidity. At your facility: your clean rooms should reflect this same temperature & humidity factor.
Substandard vacuum of 17 to 22” of Mercury around 4,550 ‘ in elevation {above sea-level} & not using an autoclave to evacuate air trapped within
the part core - will yield parts with voids: less structural integrity & heavy on Resin mass. This is far outside the original design engineers intent: -
plays havoc to meet the stress analysis factor & may fail before costly Static & Fatigue Testing is actively underway. I have seen Program Managers
turn their head due to composite assembly failure or submit false FAA reports. Do it right the 1st time out. This technology is not experimental &
yields Repeatability to accommodate all departments in support of the product. “If’ you follow all proper procedures - scrap is not an option.
Sikorsky S-92 Invar Mold Tool for Fuel Cell Sponson’s FAJ – Floor Assembly Jig to Support RH Sponson Mfg. CNC Trim & Drill Vac Tool for Carbon Parts
The 1st SOW where the Supplier uses your CAD data & design configures the best methods to build either Invar Molds, Aluminum or Composite Tooling. In
this demonstration by example, we’ll use the Invar mold tool. After a specific vendor is selected, the Invar mold is built to the most exterior mold line
of the product to control design & engineering configuration. If you link all Molds, Assembly fixtures & CNC trim & drill tools, do you have control
under {1} Statement of Work Package? Stick to schedule, be specific on the requirements with the Tooling Provider to produce accurate Tools.
RA Finish per panel must be indicated to later reduce work to the carbon fiber surface pending final primer & paint. Next: the Invar mold must have the
proper excess to vacuum bag the part & {create a test coupon sample}. Tooling holes are also in the excess area to transfer a “Cured Part” to the
CNC Fixture later toward final trim & drill per CAD part geometry. This renders final trim of each Part periphery. This is where proper Tolerance is
Specific to each Part & needs to be called out in the 1st SOW & match the scribe lines or EOP’s representing Part Periphery in the molds. Top Tier
Suppliers who build the Tooling molds, generally do not make Composite Parts. Verify in the 1st SOW that your mold line needs to be .005” to Net
Condition & call out +/- limitations on the Surface & Scribe lines. This assures QA validation & ensure you have a tool liaison person on site daily.
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4. Importance of Linking - SOW 1,2 & 3 …together
In Tool Design on the 1st SOW, it must be incorporated into the verbiage that all geometry x, y & z values to be tied into the surface of the tool
to reflect CAD design & engineering. If there is a separate system of geometry to “level the tool” it also needs to be tied into surface x,
y & z geometric values of the tool to reflect engineering & noted tolerance. This validates the proper part relationship relative to the
aircrafts design geometric attitude of the aircraft “by Position” in Projected Views, not along contour values. Maintain right angles at all
time unless noted on Shop Reference Drawings. If, along contour values are called out on the reference drawing, indicate as such.
Designate to apply: Y to = Station values STA .0000” {4 places} Body Coordinates
X to = Butt line values BL .0000” {4 places}
Z to = Waterline values WL .0000” {4 places}
• The non inertial body coordinate system is fixed in both origin & orientation to the moving vehicle.
• The object is assumed to be rigid. Such as the Master Model Based Definition {MBD} or Master Tool.
• The orientation of the body coordinate axes is fixed in the shape of body.
• The x-axis points through the nose of the Vehicle - Fwd & travels to the Aft exit surface where the BL = 0.000”.
• The y-axis points to the right of the x-axis (facing in the pilot's direction of view), perpendicular to the x-axis.
• The z-axis points down through the bottom the vehicle, perpendicular to the xy plane & satisfying the RH rule.
• Translational Degrees of Freedom. Translations are defined by moving along these axes by distances x, y, & z
• from the origin plane or start point.
• Rotational Degrees of Freedom. Rotations are defined by the Euler angles P, Q, R or Φ, Θ, Ψ.
• They are: P or Φ - Roll about the x-axis
• Q or Θ - Pitch about the y-axis
• R or Ψ - Yaw about the z-axis Unless otherwise noted: by default use Catia V5 software that utilizes ZYX rotation order for Euler angles
The 2nd SOW creates the CNC Trim Drill & fixtures & can be tied into Robotics at the Design stage, not after build, to save cost. Anticipate
extended lead times on Robotic builds. SOW # 2 Part Periphery reflects the scribe line geometry in the molds of SOW #1 to Proof.
The 3rd SOW is created by the 2nd Supplier who builds the carbon fiber part. By suggestion, using PTM & W High Temp Resin Systems, a wet
layup is suggested to “establish a trial run on the weight factor” to record data: on each part being cured, in the autoclave under
proper Nitrogen Pressure & Proper Vacuum. Most parts are ramped up to 350*F for 8 hours at required stages & ramped down to a
specific degree before part removal. If shop conditions are not controlled temperatures, be forewarned if you open the auto clave
door at 120* F to rush removal of the tool & part & the shop temp is 60 degrees F, you could loose your composite tool or create stress
cracks in the part surface between the thermal exchange. Please be advised to use the temperature requirements noted in the
advanced composite instruction methods noted from start to finish to limit errors in the material science of the product: by application.
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5. Proof of Part Weight - Analyzed in Sow 3
On SOW # 3 by Provision: Word the SOW to Reflect the EBOM or Engineering Bill of Material to validate by QA Record: {run an Excel SS of each &
every Part weight that the 1st SOW Invar Molds produced per OML geometry of Part}. List each Part # that reflects each Family of Tools by #.
 Note the Revision level on the Mold to Reflect the Rev level & match engineering MBD currently released Part per CAD data to be the same by date.
 Never use a sample part that has not met “full product design conformity” or a scrap part rejected by QA to “Rate a Tool”. It does occur today.
Weight Equals Money - The challenge of the next-generation spacecraft hinges on a few primary issues. First & foremost, of course is cost.
Once assembled, every Gram Counts to balance symmetry in product development as Scales are used to determine the weight of parts or the
advanced Production Vehicle. All components need to achieve stable, balanced conditions left to right & fwd to aft, what ever the product is.
Picture taken in MI April 2015
Compliments of NASA Renovated this- from AZ where John Wayne & Jimmy Stewart used this in movies
Above: A next-generation SUV? Advanced materials will be essential for making dramatically improved spacecraft possible. A request like this is sure to get you laughed off
the new-car lot. But in many ways, this dream car is a metaphor for the space vehicles we'll need to expand our exploration of the solar system in the decades to
come. These new spacecraft will need to be faster, lighter, cheaper, more reliable, more durable, & more versatile, all at the same time. Impossible? Before you
answer, consider how a rancher from 200 years ago might have reacted if a man had asked to buy a horse that could run & pull a wagon at 70 mph for hours on end,
carry his entire family, all their luggage, & sing his favorite songs to him all the while! Today we call them SUV’s. ;-0 Revolutions in technology -- like the Industrial
Revolution that replaced horses with cars -- can make what seems impossible today commonplace tomorrow. Ford & Edison were visionaries & hands on builders.
Such a revolution is happening right now. Three of the fastest-growing sciences of our day--biotech, nanotech, & information technology -- are converging to give scientists
unprecedented control of matter on the molecular scale. Emerging from this intellectual gold-rush is a new class of materials with astounding properties that sound
more at home in a science fiction novel or movie than on the laboratory workbench.
Imagine, by example, a substance with 100 times the strength of steel, yet only 1/6 the weight; materials that instantly heal themselves when punctured; surfaces that can
"feel" the forces pressing on them; wires & electronics as tiny as molecules; structural materials that also generate & store electricity; and liquids that can instantly
switch to solid & back again at will. All of these materials exist today… & more are on the way. With such mind-boggling materials at hand, building the better
spacecraft & tomorrow’s Sports Cars Like the Ford GT on slide 2 starts to appear not so far fetched after all. They’re a Science Experiment in the making by Record.
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6. Continuation of Slide 5 – How SOW 3 Content - Supports Design Weight…
We all like to eat, it’s our lifeline as humans to survive. That’s why we work to maintain our responsibilities to family, Country & ourselves to evolve . Like food
preparation , it’s all about recipe, texture & selection. A little bit of this & a little bit of that. We have to follow the directions for something special to be cooked
properly. If we’re baking we watch the temp, the time, the elevation to accommodate the best results for the particular meal we made to be a quality feast.
Advanced Composites in comparison to cooking is much the same & an unusual analogy, but not really. Beginning as a Pattern Maker in this Industry & Mastering the
Engineering Concepts as a SME, I’ve discovered that most all Pattern Makers, Jig & Fixture Builders & Manufacturing Engineers are very good cooks. We’re original.
When anticipating the outcome of a Composite Mold Tool, Invar Tool or Aluminum Tool Project, the method to choose which avenue of material sciences best suited
for application is very common to the desired Flavor of it’s intended use, by whom & how many units are being built. We master cooking skills for a few or large groups.
Maintenance of proper planning includes: > high temp resin systems that use the weight ratios of resin to catalyst by record: yields repeatability when proper Engineering
Principles are applied by Process & validated by ongoing QA record. Planning Operations & Inspection Steps throughout the Plan build process to the detail level of
constant surveillance & attached autoclave cure record charts; ramp up & ramp down temps by procedure to validate EOP geometry. Holes drilled per tool as
required to maintain proper edge distance. Always witness removal of Part with “QA validation present” & to trim part per SOW # 2 Trim Tool Provisions to match
the scribe line & mold line periphery. Zero scales & weigh each trimmed & drilled part with QA validation on board to record date & time. Use of this terminology
in the SOW by manufacturing engineering request with QA buy off Operations per Process Planning saves cost in later “stepped manufacturing processes”.
After each part is made, create a column on the excel SS to list the target weight Per Engineering of each part “by CAD design”. Repeat process on pre-preg parts where
the CAD Model Based Definition {MBD} is the ruling Authority. No engineering emails are engineering authority without proper ECN’s by record with a designated
ECN # or {Engineering Change Notice #} on record to trace by FAA, Customer & Client Recipient. Compare analysis of the Closest Gram weight target limits. Highlight
performance initiatives. Perform Shore Hardness on all test coupons, relative to each part. All of the above> combine into good work habits & respectable
communication at all department levels, will yield the science application behind the build process . This ensures a solid build outcome & acceptable repeatability.
Per SOW #3, after CNC Trim, validate Periphery of Part via CMM to CAD Data or use laser trackers - off the original submitted file – that created the EOP scribe lines on the
1st SOW - Invar Molds to match the same CAD file on SOW # 2. This once again reflects the same x, y & z values. Record “out of tolerance conditions as they occur”
on Planning & follow up with an Excel SS. QA can note each side that may not be within tolerance, create a NCO & reconvene with engineering by eng. disposition.
All recorded by QA & noted in the Manufacturing Engineering Manuel that aids Production efforts by Provision. Institute Proper Planning & be = @ all Vendor levels.
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7. Sow 3 Target is 1st Article Part & Configuration Conformance to “Rate all Tooling”.
Sow # 3 needs to incorporate specific word content as SOW # 1 & 2 that EOP Trim liability needs to reflect proper Setback {generally .062”} of SOW # 2
Scribe lines from SOW # 1 EOP & be within a proper governed tolerance of QA acceptability. Hence: if parts are Trimmed through fabrication on
SOW # 3 “that do not fall within the Engineering Trim Scope of a Proper Part Configuration per CMM Quality check off the CNC Trim Fixture”, the
CNC Trim Fixture must be returned to the 1st Supplier who made the CNC Fixture for “re-tooling” to make it right per the Original # 2 SOW Package
configuration CAD Data content & assume the cost of repair. Conditions of Supply & loss of Material {Carbon fiber, resin or pre-preg + labor} “Must
also be taken into consideration to correct noted errors ”for loss & Part Protection “ not to be incurred by the Receiving Customer or Client provider
{noted as Customer on SOW # 3 contract} or known as the Carbon Fiber Part Supplier - Manufacture. Incurred expenses of error by the # 3 Sow
Provider needs coverage by Supplier # 1. Establish a Condition of Credit per SOW # 3 & noted in SOW 1 & 2 by “word content” to ensure coverage.
All advanced carbon fiber based products …… have the same designated objective per the EBOM …… & MBOM to produce a high level of Quality…
This: “language or content written into the 1st & 2nd SOW Packages resolves fit, form & function liability back onto SOW # 1 & 2 Provider being Validated by
SOW # 3 on the 1st Article Part”. This creates Insurance to provide Proper Tooling before it’s delivered to the Assembly Facility of the receiving
Production facility Customer {either in the US or abroad}: that may later manufacture their own carbon fiber parts after the 1st Article Part is
“Qualified” & delivered. This function also validates & “Rates each & every tool” by Provision prior to shipment to the receiving production facility.
The assignments I’ve worked, the FAA approached me in 2004 to assist them from the broad composite knowledge base to help & establish Solid Provisions
on a US & International level - to create Guidelines to enhance the Industry. I spent the next 10 years perfecting this mission objective at my cost.
May 2015 Polar Aero Structures created this aid in Science Technology to assist Automotive & Aerospace Industries to Advance Thru IT by D. Lenhard - polaraero2015@aol.com
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8. All Systems Take Organized Planning & Proper Team Communication to Move Fwd >>>
∞ Even the Smallest of Details are Important ∞
Enclosed will ease production tooling requirements with advanced networking applications.
Assembled from decades of R&D of what works in Industry & what to avoid.
Optimize Group Potential are Key Goals with “Qualified & known Suppliers”
* assist in new LO platforms or re-tool efforts.
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