Lockheed Martin F-35 Joint Strike Fighter Automated Electronic Mate and Assembly System
Fort Worth, TX

With an aging fleet of fighters, the U.S. Department of Defense (and their international partners) needed a new next-generation, multi-role fighter that was as affordable as it was lethal. The resulting F-35 Joint Strike Fighter (JSF) contract was awarded to Lockheed Martin, in Fort Worth, TX, who called on AIT, as their prime contractor, to deliver an automated Electronic Mate and Assembly System – or EMAS.

Achievements

• Met affordability challenge with AIT technology, integration, and equipment
  • Supporting three aircraft variations, significantly reduced labor and equipment costs with its flexible assembly automation
• Delivered superior quality in final assembly by successfully integrating Laser Tracker technology  
  • First test plane close to that of a production quality aircraft
  • "Stealth signature" of aircraft maintained with clean lines
• Accelerated speed to market and military advantages from curtailed cycle and ramp-up times

Electronic Mate and Assembly System
AIT developed its Electronic Mate and Assembly System to perform the final mating of the JSF forward, center, and aft fuselage assemblies as well as the wing assembly. Its engineers designed the assembly stations with the flexibility to mate the three F-35 variants called for in the contract: the F-35A, F-35B, and F-35C, each manufactured for specific uses by the military. With three variations being assembled on the same line, the goal of affordability was easily met because tooling costs for each aircraft were eliminated. 

Quality construction was also critical to the cost-containment objectives set by the DOD. Two major factors contributed to the superior quality and processes in the F-35 assembly: 

• Laser Trackers in the AIT EMAS guided the positioners into a precise mating configuration for each aircraft component.
• EMAS software mated the components in virtual space before the actual physical mating occurred.

Because of the incredibly accurate automated measurements, the assembly schedule was also reduced, resulting in additional time and cost savings. In fact, the first test plane boasted near-production quality and its required "stealth signature." 

The F-35 JSF project was the first at Lockheed Martin’s Fort Worth facility to employ this type of automated system.  AIT technology helped accomplish the U.S. DOD’s overall goal of creating the most advanced stealth fighter to date while reducing costs and achieving affordability. 

Our expert coordination equates into a competitive advantage in time to market and cost containment for our Aerospace partners.