Composite Panel Repair Tool

GROUP GGUSTAVO CORREA,

JOHN KEARNEY, SENG HOU LOI (NICHOLAS),

 MARC POYNTER, OWEN LAU

The problem

Time consuming Not that accurate

Dips or high spots in surface can cause disbond in replacement skin.

Can also affect airflow, and possible interference with other surfaces.

Standard procedure

Cut out damage by hand with cutting wheel or grinder etc.

Shaping replacement core by hand sanding Use angle grinder. Use DA sander. Use flat long block for best possible hand finish.

Our solution

Vacuum Suction Mount

Router

Damage Cutout

Aircraft Flap

Bar Slide

Our SolutionBonded in replacement CoreNeeds Trimmed to Match Existing Contour.

Our Solution

Rollers Follow Existing Contour Around Repair Cutout to Trim Replacement Core to Match

Patent Patent is a government license conferring a right to

exclude others from making, using or selling an invention.

A patent is issued to an individual inventor and not the company.

Websites to search for patents : 1. https://patents.google.com/2. http://www.uspto.gov/

Step Sanding Tool Kitsby Dark Matter Composite Ltd

List Price: £ 1,700 ~ £ 2,000 

HOUSE OF QUALITY

WHATS

HOWS

Overall Decision Matrix

How to Secure our Jig

Potential materials Aluminum Polymers

Injection Molding Parts Teflon Nylon Polypropylene

Reasons: Durable Light weight Chemical ResistantAcetone, alcohol, MEK (Methyl Ethyl Ketone)

FMEA

FMEA

FMEA

FMEA

FMEA

FMEA

Manufacturing 

Plastic production suppliers from Asia. Lower material and labor cost. Polypropylene (PP) is chosen because it is cheap and durable. The cost of production (including electricity and labor cost) for

plastic molding is approximately USD 6.50 per hour in Asia. Suppliers use NISSEI Injection Molding Machine to produce our

plastic parts. FedEx Freight Shipping from Asia to Los Angeles, then UPS

ground shipping to Indianapolis.

Nissei Injection Molding Machine

Injection Mold

Type of Plastic

Material Cost for Plastic Production

Total Cost (Plastic)Per Assembly

Local Supplier Cost

Grand Total Cost Per Assembly

SALARIES

INFRASTRUCTURE

PROFITS