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This paper reviews today's aircraft wing production assembly methodology and technologies as well as innovative ideas for advancing the high-level wing assembly state-of-the-art. Automated wing assembly systems are only being utilized to rivet/fasten first level subassemblies like panels, spars, and ribs. All other high level assembly tasks are performed manually, incurring associated increases in recurring costs due to production inefficiencies, long lead times, expensive rate tooling, and difficult assembly tasks performed inside small wing compartments. Existing assembly methods, process parameters, and the process characteristics of manual, machine, and man/machine systems provide many opportunities for improving wing assembly.

Assembly techniques for the majority of expendable and reusable launch vehicles have not changed much over the last thirty years. Some progress has been made, specifically on new programs, however, improvements on existing expendable launch vehicle production lines can be difficult to justify; even more so for one or two reusable vehicles. This presentation will focus on techniques and systems used for manual and automated assembly of expendable and reusable launch vehicle primary structures. Today's assembly is characterized by manual operations involving fixtures and templates, and all tasks are carried out primarily with single function hand tools. Typical assembly approaches used for metallic and composite primary structures will be discussed. Potential opportunities for process improvements utilizing advanced hand tools, mechanized and/or automated equipment will be addressed.