CMSC 2024

The Edge Coating Verification (ECV) process has been transformational to F-35 production and quality in Fort Worth and throughout the world. The team integrated 3D scanning automation to verify the application of F-35 component edge coatings, driving down variation and ensuring adherence to engineering and performance requirements (process known as seam validation). The Edge Coating Verification process was originally developed in 2017 for F-35 Component Final Finishes to mitigate downstream seam validation issues in assembly. In 2023, the team completed integration of two automated industrial robotic scanning cells in Fort Worth to further increase scope/efficiency and support F-35 rate requirements.

An intuitive user interface guides an operator through the proper steps to setup panels within the cell. Optical projectors, in-cell displays, and cameras are integrated in the work cells to errorproof the process and enhance operator repeatability. The panels are fixtured in the work cell with Lockheed Martin developed vacuum cup standoffs that are compatible with 107 unique panels across the three F-35 variants. The standoffs quickly secure and elevate the part, allowing the systems to scan both the outer and inner planes of all edges.

The scanning robot cell is a commercial off-the-shelf system. After the operator sets up the panel in the system, an industrial robot manipulates a 3D laser scanner to automatically collect surface data along a pre-programmed path. All data needed to generate a report is collected within minutes, compared to the legacy manual process that took 2-3 times longer per panel. Complex and robust metrology analysis algorithms automatically compare scan data of coating conditions once scanning is complete. Easily interpretable reports are produced to guide any operator rework and corrective action activities necessary.

Impact
Significantly reduced coating variation to help meet 100% Quality/On-Time Goals.
Reduced downstream scrap, rework, and repair (SRR) hours by identifying any issues prior to panels leaving the coatings facility.

Future
Partner sites, both domestic and international, are leveraging the new “standard” for edge coating verification in support of seam validation. This means supporting sites can avoid development costs and inspect with the same tools to the same standard across the program, both during initial manufacturing all the way through depot maintenance teams.
Most recently, an additional Aeronautics site is implementing a similar solution based on the success of the integrated Fort Worth systems. Future expansion of this automated metrology solution is very strong with the support of the suppliers and Operations Technology team.

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