A faster, more precise way to create cockpit enclosures may end up saving the F-35 Lightning II program a significant amount in manufacturing costs. The Office of Naval Research (ONR) has invested in an automated thermoforming process that could cut costs by as much as $125 million over the course of the Joint Strike Fighter program.
An F-35 canopy — the transparent enclosure over the cockpit — has an unusual shape and specialized material that make the manufacturing process more complex than that for other aircraft. Now what used to take up to six days to make will take only four days or less. The new automated process also will require fewer tools and help avoid costs when aircraft require replacement canopies.
Currently, skilled technicians load a preformed acrylic shell into a forming tool and put it in an oven where it heats at 200 degrees or more for up to six days. During that time, workers regularly enter the oven to observe the canopy’s progress and manually adjust positioning clamps to control the forming process. Managing this process is critical for optimal canopy performance.
The new cost-effective method employs a control system with four cameras that can see inside the oven to calculate the rate at which the canopy’s shape is forming. The clamps then automatically adjust to ensure the shape remains uniform throughout the process to meet the F-35’s stringent performance requirements.
