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Probabilistic methods are used in calculating composite part design factors for, and are intended to conservatively compensate for worst case impact to composite parts used on space and aerospace vehicles. The current method to investigate impact damage of composite parts is visual based upon observation of an indentation. A more reliable and accurate determinant of impact damage is to measure impact energy. RF impact sensors can be used to gather data to establish an impact damage benchmark for deterministic design criteria that will reduce material applied to composite parts to compensate for uncertainties resulting from observed impact damage. Once the benchmark has been established, RF impact sensors will be applied to composite parts throughout their lifecycle to alert and identify the location of impact damage that exceeds the maximum established benchmark for impact.

“One shot” drilling and countersinking multiple stack ups of dissimilar materials with automated equipment requires a system of elements and controls. Each of the elements necessary to drill and countersink multiple stack ups of dissimilar materials in a single operation has been successfully combined and applied to an automated system. An explanation will be provided for the use of Microsoft Excel, standard drill libraries and math formulas to rapidly determine and insert the proper end effector position and drill/countersink commands into the machine control programming code. Surface location identification for coordination of the machine time and measurement based coding and the machine components necessary to interact with the time and measurement based machine code will also be explained.