Accession Number : ADP006034

Title :   Prototype Manufacturing Techniques for Reducing Cost, Schedule, and Technical Risk,

Corporate Author : BOEING MILITARY AIRPLANE CO WICHITA KS

Personal Author(s) : Schuessler, M. S. ; Williams, Joseph C.

Report Date : SEP 1987

Pagination or Media Count : 14

Abstract : This paper explores techniques employed by the Boeing Military Airplane Company to efficiently produce prototype flight hardware. A number of fabrication methods presented herein were developed during the company funded Brave 200 and Brave 3000 Autonomous Vehicle Programs. Experience gained during other prototype/short production run activities is also included. Since CAA and CAD are now standard up front engineering procedures (aerodynamics, surface lofting, stress models), the computerized information can be readily adapted to automated tooling and manufacturing activities. Accurate master models traditionally consume a great deal of tooling flow time and represent a significant cost item. Three examples of low cost master models by computer assisted techniques are: (1) N/C scribed header templates; (2) N/C cut precision data sets; and (3) N/C machined models. By adapting complete surface definition data sets, a 50 percent reduction in master model costs can be realized over traditional model generation methods. Once models have been generated, several options exist when constructing fabrication tooling. Dependent upon program objectives, a particular level of tooling, from soft to hard, may be selected. Plaster layup tools for composites have been developed as a highly reliable, lowest cost method for single part advanced composites fabrication. Cast epoxy compression molding tools have yielded excellent results for up to 12 parts under standard molding temperatures and pressures. Electroformed nickel has proven to be a cost effective prototype tooling technique which can be transitioned into production.

Descriptors :   *COST ANALYSIS, *MANUFACTURING, *AIRCRAFT, ACCURACY, AERODYNAMICS, AUTOMATION, COMPOSITE MATERIALS, COMPUTER APPLICATIONS, DATA BASES, ELECTROFORMING, FABRICATION, FLIGHT, FLOW, INSTRUCTIONS, LOW COSTS, MODELS, MOLDINGS, NICKEL, PRODUCTION, PROTOTYPES, RISK, SHORT RANGE(TIME), STRESSES, TEMPERATURE, TIME, TOOLS.

Subject Categories : Aircraft
      Economics and Cost Analysis

Distribution Statement : APPROVED FOR PUBLIC RELEASE