Rapid Boot Installation

ARC is the current supplier of boot kits for a high volume airframe program and has the existing capabilities to manufacture the materials and develop the technologies required for this SBIR. We hold a secret facility clearance (including MP3) and our AS9100 quality system is registered and current. From our past experience we are prepared to develop and demonstrate novel manufacturing processes for final finish treatments to panels, doors, and structures in order to radically reduce labor hours and manufacturing cycle times. Our approach will include Pre-molded (i.e. complex injection molded configurations) parts that will significantly reduce the overall piece count at installation; formed “tips” to reduce fracture at apex points; and thermoforming complex curves to simplify material application. While this process will ideally focus on final finish placement on fully-assembled airframes, component-level efforts will also be addressed as we are evaluating a thermo-plastic over-molding technology for “one shot booting” of complex door and panel configurations as well. We anticipate that these approaches will cut final finish time and reduce or eliminate vacuum bagging at assembly. BENEFIT: Upon successful development of the reduction of boot kitting and OML process, ARC could offer these same processes to other branches of the Military as an alternative to current processes. These approaches will significantly reduce current production methods and cycle times. These new production methods will be made available to naval ships and other types of fixed wing and rotor aircraft as well as unmanned air vehicles.