HGU-99/P Improves Safety Aboard Flight Decks
June 5, 2023HGU-99/P Improves Safety Aboard Flight Decks
June 5, 2023REAL-WORLD IMPACT
Fastener Measurement Tool Enables F-35 Rate Production
Lockheed Martin Predicts F-35 Lifecycle Program Costs Savings of $13M
To achieve effective stealth performance, advanced military aircraft require extremely smooth outer surfaces. More than 40,000 threaded fasteners secure aircraft surface panels, and each fastener must meet precise depth and flushness tolerances. Accurate inspection at multiple stages of manufacturing is critical.
Traditional measurement methods lacked the required speed, accuracy, and repeatability. They were difficult to use in tight or curved areas and depended heavily on operator skill. A faster, more reliable, and highly accurate solution was needed to reduce inspection time and lifecycle cost.
Creare Innovation
Through Air Force and Navy SBIR funding, Creare developed the foundational Fastener Measurement Tool (FMT) technology to meet the demanding requirements of the F-35 Joint Strike Fighter program.
The FMT uses a multi-line laser scanner to generate a high-resolution 3D point cloud of the fastener and surrounding aircraft surface. Advanced data processing algorithms calculate fastener depth relative to the aircraft mold line, delivering a clear pass/fail indication in less than two seconds. The system performs reliably on curved surfaces and provides significantly improved repeatability compared to manual methods.
The original proof-of-concept demonstrated that high-speed, automated laser-based inspection could dramatically improve accuracy while reducing dependence on operator judgment.
Edare’s Role: Productization, Manufacturing & Deployment
Following successful prototype validation, the FMT technology transitioned to Edare for full product development, production, delivery, and end-user support. Edare transformed the SBIR-funded prototype into a robust, production-ready inspection system suitable for high-rate aerospace manufacturing environments. This included engineering refinements for manufacturability and durability, precision assembly and calibration of high-fidelity laser measurement heads, integration of the wearable processor and power systems, quality-controlled manufacturing and system validation, and field deployment, operator training, and ongoing support
The result is a lightweight, handheld measuring head with integrated digital display, paired with a belt-pack processor that stores measurement data for traceability and further analysis. The portable system enables inspection anywhere on the aircraft, both before and after conformal fill application.
Edare ensures each system meets stringent aerospace quality standards while delivering repeatable performance on the production floor.
Measurable Impact
The FMT has been heavily integrated into the F-35 program, as well as on 18+ other platforms. On F-35 alone, the FMT has delivered substantial operational and financial benefits:
- F-35 Cost Reductions
- Projected production lifecycle cost reduction exceeding $13 million for fastener flushness inspection labor savings, a 50% reduction in hand-touch labor associated with these inspections (based on initial Lockheed Martin evaluation)
- Additional savings are not quantified here for Countersink and Fill Inspection.
- Reduced Quality Escapes
- Rapid pass/fail results allow mechanics to inspect and address problem areas at the time of install. This dramatically reduces costs associated with SRR (Scrap, Rework and Repair).
- Operational Efficiencies
- Purpose built for the production floor and sustainment arenas
- One tool replaces several reducing the burden on tool maintenance groups.
- Rapid training and best-in-class ease of use.
- Several hundred operators have been trained on the system, 10’s of millions of measurements have been made.
By bridging advanced research and real-world production, Edare plays a critical role in transforming Creare’s SBIR-developed technologies into deployable, production-grade systems. The Fastener Measurement Tool exemplifies this model: innovation initiated through research, matured through engineering, and delivered at scale through precision manufacturing and lifecycle support — driving measurable performance improvements across advanced aerospace platforms
defining success
Fastener Measurement Tool Enables F-35 Rate Production
HGU-99/P Improves Safety Aboard Flight Decks