The integration of metrology, NDI, automated scarfing, automated ply cutting, laser projection, automatic ply verification, and a cell controller into a series of "repair cells" has the potential to significantly improve the quality and efficiency of repairing composite structures. A team of technology suppliers is developing systems and processes for the repair of manufacturing defects for new aircraft programs. Under a DoD Commercial Technologies for Maintenance Applications program (CTMA), the team is also evaluating and integrating system components in the context of supporting repair of C-130 radomes. All data (original design model, reverse engineered surfaces, NDI) is referenced to a common coordinate system, enabling enhanced analysis with combined inspection modalities. Shearography data has been overlaid onto surface data and displayed on the radome to compare with tap test results. This paper describes the approach, technologies and results through 2009.

Presented at SAMPE 2010 Conference and Exhibition on Wednesday, May 19.