Portable Digital Metrology System for Measurement of Defects on Optically Transparent Canopies and Windscreens

TECHNICAL POINT OF CONTACT (TPOC)
Kristiana Topasna
Jaime Santiago
PROJECTED CMMC LEVEL REQUIREMENT
Level 2 (Self)
TECHNOLOGY AREAS
None
MODERNIZATION PRIORITIES
Sustainment & Logistics
KEYWORDS
Transparency; Acrylic Outer Ply; Canopy; Window; Windscreen; NDI; Optical Zone; Scratch and Pit Measurement
OBJECTIVE
Develop a portable digital metrology system to measure aircraft transparency damage (such as coating damage, scratches, cracks, or pits) that can be used on aircraft by squadron level maintenance personnel to characterize damage.
DESCRIPTION
Scratches and pits to the acrylic outer ply of canopies and windscreens cause optical distortion as well as structural vulnerability, and these types of damage cause significant readiness degradation. Repair methods for these defects are dependent on the severity of the damage which is determined by the dimensions of the defect. Currently available repair methods are limited and repair limitations are stringent and highly dependent on the severity of the defect. Inaccurate measurements could be the difference between a repairable asset and a scrapped transparency. Currently the only portable method for characterizing defects on aircraft transparencies is an optical micrometer. This tool is user-dependent, not ergonomic, and requires extensive training to be performed accurately. Due to the transparent material, it is also difficult to perform measurements with an optical micrometer on-aircraft or in outdoor environments and requires the removal of the canopy or windshield.
Candidate measurement concepts shall be executable on aircraft and capable of performing defect measurements (e.g., scratch defect with length 1 , width << 0.125 , and approx. depth of 0.100 ) on optically transparent materials.
PHASE I
Define and develop a measurement concept and portable tool that can meet the requirements listed in the description. Perform analysis or testing to demonstrate measurement concept and portable tool performance.
The Phase I effort will include prototype plans to be developed under Phase II.
PHASE II
Develop and demonstrate a prototype tool and/or process that meets the requirements listed in the Description. Prototype testing and demonstration shall be performed at the canopy shop at Fleet Readiness Center Southwest North Island.
PHASE III DUAL USE APPLICATIONS
Perform final testing at organizational and intermediate level repair locations and transition for use on naval aircraft. Final testing shall include (at a minimum): total time and training required for full competency by a new user, precision/accuracy of measurement results in comparison to existing measurement tools, clarity and completion of documentation or measurement display provided to the end user, and applicability of tooling across multiple aircraft platforms/transparency materials.
This technology has significant dual-use potential for commercial airline Maintenance, Repair, and Overhaul (MRO) and automotive glass inspection.
REFERENCES
MIL-PRF-25690 Plastic, Sheet and Formed Parts, Modified Acrylic Base, Monolithic, Crack Propagation Resistant, https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=18093
MIL-PRF-8184 Plastic Sheet, Acrylic, Modified, https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=6865
MIL-PRF-5425 Plastic, Sheet, Acrylic, Heat Resistant, https://quicksearch.dla.mil/qsDocDetails.aspx?ident_number=5396
NAVY SBIR 25.2-087 Repair Solution for Optically Transparent Canopies and Windscreens, https://www.navysbir.com/n25_2/N252-087.htm
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