Note: This article was published in 2018. We updated the article in 2025 to include a rendering and more information regarding the project.
Aerobotix, an AS9100-certified FANUC robotics integrator for the aerospace and defense industries, recently received final acceptance to begin production spraying on five types of aircraft radomes. Subsequently, Aerobotix was challenged by Robins Air Force Base (RAFB) to design a turnkey robotic paint system capable of applying high-performance coatings to the C-17, C-5, C-130, F-15, and Talon II aircraft.
Engineering Challenge: One System, Five Aircraft Types
The radome sizes and coatings vary greatly across these aircraft platforms. However, RAFB had access to only one spray booth and funding for a single robotic system. Therefore, this constraint required innovative engineering to create a versatile solution. Additionally, the system needed to handle dramatically different part geometries and coating specifications.
Aerobotix then leveraged FANUC RoboGuide offline simulation software to concept a turnkey robotic coating system. Furthermore, they designed an end-of-arm tool capable of processing all areas of each radome type. Consequently, the simulation capability proved critical in validating the system’s versatility before physical installation.
Comprehensive Turnkey Solution
After receiving the contract, Aerobotix delivered a complete turnkey robotic painting and inspection solution. This included building the system, developing all coating process parameters, creating path programs for each aircraft type, and validating coating performance for every part. Next, the team installed the system on-site and trained RAFB personnel to operate the equipment.
The transformation was significant for base operations. Previously, painters worked in hazardous chemical environments. Now, they operate the robotic system from an air-conditioned control room. As a result, this dramatically improved working conditions and safety.
Ongoing Partnership and Training
RAFB strategically saved a sixth component—the C-130 Spinner—as a training opportunity. After installation, Aerobotix remained on-site to guide RAFB personnel through the complete process. They helped develop coating parameters and path programs for this final part. Ultimately, this ensured the customer gained full operational independence.
This project demonstrated how innovative robotic solutions can consolidate multiple coating requirements into a single, efficient system. Moreover, it improved both operational efficiency and worker safety.
