Aerospace Product Development | Injection Molding | Qualification Testing
Challenge
Aircraft fuel-tank fasteners require durable environmental protection, but the legacy sealing process was slow, labor-intensive, and difficult to standardize.
Aircraft fuel-tank fasteners require durable environmental protection, but the legacy sealing process was slow, labor-intensive, and difficult to standardize.
My contribution
I led the mechanical development of a two-part cap-seal system through approximately 15 design iterations and more than 40 requirements. I developed the attachment ring and protective shell, selected materials and joining methods, coordinated Boeing-approved suppliers, and translated prototypes into injection-molded and ultrasonically welded production hardware.
I led the mechanical development of a two-part cap-seal system through approximately 15 design iterations and more than 40 requirements. I developed the attachment ring and protective shell, selected materials and joining methods, coordinated Boeing-approved suppliers, and translated prototypes into injection-molded and ultrasonically welded production hardware.
Verification
The program included more than 100 lightning, mechanical, environmental, pressure-washer, kick, and stomp-and-twist tests. I worked across design, manufacturing, suppliers, and test teams to resolve failures and refine the product.
The program included more than 100 lightning, mechanical, environmental, pressure-washer, kick, and stomp-and-twist tests. I worked across design, manufacturing, suppliers, and test teams to resolve failures and refine the product.
Outcome
The final approach reduced installation time from approximately seven minutes to seven seconds and contributed to four U.S. patents.
The final approach reduced installation time from approximately seven minutes to seven seconds and contributed to four U.S. patents.
