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The performance enhancement of a vertical tail provided by aerodynamic flow control could allow for the size of the tail to be reduced while maintaining similar control authority. Decreasing tail size would create a reduction in weight, drag, and fuel costs of the airplane. The application of synthetic jet actuators on improving the performance of the vertical tail was investigated by conducting experiments on 1/9th and 1/19th scale wind tunnel models (relative to a Boeing 767 tail) at Reynolds numbers of 700,000 and 350,000, respectively. Finite-span synthetic jets were placed slightly upstream of the rudder hinge-line in an attempt to reduce or even eliminate the flow separation that commences over the rudder when it was deflected to high angles. Global force measurements on the 1/9th scale model showed that the flow control is capable of increasing side force by a maximum of 0.11 (19%). The momentum coefficient that created this change was relatively small (Cμ = 0.124%).

Since the 1960's, lightning protection of aircraft has been an important design aspect, a concern for the flying public, aircraft manufacturers and the Federal Aviation Administration (FAA). With the implementation of major aircraft structures fabricated from carbon fiber reinforced plastic (CFRP) materials, lightning protection has become a more complicated issue to solve. One widely used material for lightning strike protection of CFRP structures within the aerospace industry is expanded metal foil (EMF). EMF is currently used in both military and commercial passenger aircraft. An issue that has historically been an area of concern with EMF is micro cracking of paint on the composite structure which can result in corrosion of the metal foil and subsequent loss of conductivity. This paper addresses the issues of stress and displacement in the composite structure layup which contribute to paint cracking caused by aircraft thermal cycling.

In the wake of the 9/11/2001 hijacking events, the Federal Aviation Administration (FAA) has emphasized the need for enhanced flight deck doors on commercial airplanes. The paper describes enhanced flight deck door, which meets the new FAA requirements for intrusion resistance and ballistic protection. In addition, the new door meets the existing requirements for rapid decompression, flight crew security and rescue.

Clothing accounts for a surprisingly large quantity of resupply and waste on the International Space Station (ISS), of the order of 14% of the equivalent system mass (ESM). Efforts are underway in the ISS program to reduce this, but much greater changes are likely to be possible and justifiable for long duration missions beyond low Earth orbit (LEO). Two approaches are being assessed for long duration missions: to reduce the mass of the wardrobe through use of lighter fabrics, and to clean clothing on board for reuse. Through good design including use of modern fabrics, a lighter weight wardrobe is expected to be feasible. Collateral benefits should include greater user comfort and reduced lint generation. A wide variety of approaches to cleaning is possible. The initial evaluation was made based on a terrestrial water-based washer and dryer system, as this represents the greatest experience base.

The Boeing Company has developed a mobile robotic drilling and fastening system for use in assembly processes on the lower panel of a horizontally fixtured wing. The robotic system, referred to as Lower-panel Drilling and Fastening System (LPDFS), was initially developed as part of an initiative to minimize facilities costs by not requiring costly foundation work. It is designed to operate with a high level of autonomy, minimizing operator intervention, including that required for machine setup and tool changes. System design enables positioning the work piece at a lower ergonomic height for concurrent manual processes. In all aspects of design, the system will maintain maximum flexibility for accommodating future manufacturing changes and increases in production rate, while meeting the strict accuracy requirements characteristic of aircraft manufacturing.

Large diameter, tightly toleranced fastener patterns are commonplace in aerospace structures. Satisfactory generation of these holes is often challenging and can be further complicated by difficult or obstructed access. Bespoke tooling and drill jigs are typically used in conjunction with power feed units leading to a manual, inflexible, and expensive manufacturing process. For 777X flap production, Boeing and Electroimpact collaborated to create a novel, automated solution to generate the fastener holes for the main carrier fitting attachment pattern. Existing robotic automation used for skin to substructure assembly was modified to utilize extended length (up to 635mm), bearing-supported drill bar sub-assemblies. These Long Assembly Drills (LADs) had to be easily attached and detached by one operator, interface with the existing spindle(s), supply cutting lubricant, extract swarf on demand, and include a means for automatically locating datum features.