Automated painting system gets aircraft back in the sky 80% faster, saving U.S. Air Force $8.8 million since 2016
HUNTSVILLE, Ala. — Aerobotix, an AS9100-certified FANUC robotics integrator, today marked having supported the 40th restoration of air inlet ducts on F-22 Raptor aircraft. This work is part of a maintenance contract with the U.S. Air Force
SBIR Funding Drives Innovation
The Air Force’s Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) programs provided funding for the project. Aerobotix developed an automated painting system that restores the performance coatings on F-22 air inlet ducts. The system works far more quickly, cost efficiently and accurately than manual methods. Aerobotix refurbished its first F-22 in 2016. The company is on track to restore its 50th by early 2023.
“Our robotic technology can paint these units using only about 300 hours of labor, rather than 1,600 hours,” said project manager Bret Benvenuti, a senior robotics engineer at Aerobotix. “That’s a labor saving of around 80%. It really solves the challenge of getting these aircraft back into service quicker. We estimate that since 2016, we’ve helped the Air Force save $8.8 million – $220,000 per aircraft – in maintenance costs.”
Enhanced Performance and Quality Control
On jet aircraft, inlets ensure smooth airflow into engines despite turbulent air coming at the ducts from multiple directions. Aerobotix’s automated painting solution for inlet duct maintenance achieves major labor savings. It also improves accuracy and quality control. This gives F-22 aircraft a better performance signature against radar.
Additionally, the automated system can apply more coating before the material’s pot life expires. This significantly reduces waste. The highly engineered coatings cost around $1,000 per gallon. More efficient use can save about $40,000 per aircraft.
Improved Worker Safety
System Capabilities and Upgrades
Aerobotix’s system uses two robots working at the forward and aft ends of the ducts to sand and spray-coat them. Three automated systems have been installed at the F-22 Depot at the headquarters of the Ogden Air Logistics Complex at Hill Air Force Base, Utah.
Recent system upgrades include adjustable spray paths. These accommodate aircraft that need only the bypass screen areas of the inlets to be recoated. They can also spray the exterior of the inlets’ forward outer lip area. Coating the lip area while the aft robot sprays the inlets saves between two and three days in labor. Aerobotix is now looking to also use the robots to simultaneously coat other exterior sections of the aircraft. These include chines and tines, which will achieve further labor savings. In addition, Aerobotix has integrated a Terahertz measurement device. This delivers efficiency and quality improvements.
Expanding to Other Aircraft Programs
Aerobotix has also developed similar automated painting systems for coating the F/A-18E and F/A-18F Super Hornet and F-35 Lightning II. Those aircraft are featured in the blockbuster movie “Top Gun: Maverick.”
“These are some of the Air Force’s best fighter jets,” added Benvenuti. “Aerobotix is proud that our technology is supporting the jets’ combat readiness by getting them back in the sky faster. When you see the aircraft flying overhead, it really gives you a sense of accomplishment.”
A short video that the Air Force produced about its partnership with Aerobotix can be viewed here: https://youtu.be/gSxldzMc3eQ.
About Aerobotix
Headquartered in Huntsville, Alabama, Aerobotix is an innovative leader in robotic solutions for the aerospace and defense industries. The company specializes in the creation of cutting-edge automated robotic solutions for high-value, high-precision components, aircraft and vehicles. Aerobotix has more than 130 robotic systems installed in the U.S. and abroad. These systems provide exceptional results and savings for our clients.