In the December 2016 issue of the DoD’s Manufacturing Technology Program, or ManTech, the Navy heralded an F-35 Lightning II canopy polishing system developed by Aerobotix as a success story. Their effort to adapt and implement a cost-effective solution to a tedious task could save the department nearly $170 million.
The problem is not clear
According to the publication, an F-35 canopy forms a continuous shell. It represents the largest component thermoformed out of acrylic material. The heat-and-stretch process typically leaves “textures” on the inside and outside of the canopy. Workers currently remove these blemishes by hand. The task involves tedious, labor-intensive work using a vibrating sander. Removing too much acrylic can lead to considerable cost to refurbish or replace the part. It can also pose a risk to pilots during flight operations.
If a robot can sand, maybe it can polish
An Air Force Small Business Innovation Research program influenced the idea to use a sanding robotic system. To prove viability, Aerobotix integrated an industrial robot and sanding head end-of-arm tooling with different-sized grits. The system removes scuffs and polishes with rouge. Demonstrations on sub- and full-scale parts showed the effectiveness and clear results of a turnkey system.
A clear vision of the future
A $1.1 million investment proved that the advanced robotic technology could meet F-35 program requirements. Furthermore, Navy ManTech determined reductions in process variability. The system also reduced the amount of touch labor to produce a single transparency. It decreased manual labor in the initial transparency-forming process.
The same solution can apply to F-18 canopies, making a larger impact on America’s aircraft fleet. The full case study can be found on our Case Studies resource page.
Editor’s Note: This article was originally published in 2010. Updated in 2025 to reflect the continued relevance of industrial automation in the defense industry.
