1. Portable Large Shape Inspection System Project Presentation NCMS/CTMA Conference April 19, 2005

2. Overview WR-ALC Introduction Reconfigurable Press Fabrication Tools Urgent Need / Solution Project Team Project Tasks Wrap-up Presenter: Clayton Holt WR-ALC Project Manager

3. WR-ALC Introduction Warner Robins Air Logistics Center. Worldwide management and engineering responsibility for repair, modification, and overhaul of:

4. WR-ALC Operations 14000+ people…20+ percent are contractors –Engineers, Contracting, Logistics, Acquisition, Support Product support for almost 3400 aircraft –U-2, F-15, C-130, JSTARS, C-5, C-141, C-17, SOF/CSAR, CH-53 Large F-15 and C-130 international programs –RSAF, Japan, Israel, Poland, Romania, many more

5. Reconfigurable Press Film Clip

6. Stretch Forming Process Film Clip

7. 700 Fabrication Tools WR-ALC recently became ISO-9000 certified 700 fabrication tools like those shown here must now be re-certified annually … Stretch Form Die Metal Bonding Tool

8. Urgent Need WR-ALC needs a very high performance surface scanner: –To support re- configurable press operations –To certify its 700 fabrication tools annually

9. Search for Solution AFI-based scanners Prototype tested extensively by WR-ALC in 2003 and met key specifications. Had two key limitations: –Was not portable –Needed special dark room

10. AFI Animation Film Clip

11. Accordion Fringe Interferometry Invented at MIT around 2000. Based on two very simple principles: –Interference of light passing through two pin holes to generate a bright, accurate fringe pattern –Triangulation with digital camera Fiber or laser diode Collimating lens Grating Objective lens Pin Holes Interference fringes

12. What’s the “big deal”? Dense point clouds Non-contact, dense point clouds are the universal way to make 3D measurements. High performance/cost AFI lends itself to production of high performance, simple, low cost systems. A “disruptive” technology? Accordion Fringe Interferometry

13. Project Team End user: WR-ALC Program manager: Bill Waddell, NCMS/CTMA Industrial partners and other participants: –US Navy (Naval Foundry and Propeller Center) –Dimensional Photonics International (DPI) –Manufacturing Resources, Inc. (MRI) –GFM/AGFM Corporation

14. Key Project Tasks Task 1: Develop Detailed Requirements Task 2: Engage Software Vendor Task 3: Develop AFI 5000 Subsystem Task 4: Develop AFI 5000P System Task 5: Develop Press Support Frame Task 6: Deliver and Test the AFI 5000P Task 7: Application Demonstrations

15. Key Developments Sensors: Laser projector + digital camera –reduce size, increase stability & accuracy New AFI 5000 projector Prototype projector Software components –Basic software development kit (SDK) development –Application software Crossbar –Needed for portability –Bar shown is > 100 X better

16. Wrap-up Questions? Clayton Holt, WR-ALC clay.holt@robins.af.mil (478) 222-4721 Scott Ackerson, DPI scott.ackerson@dphotonics.com 484.888.2379