TECHNOLOGY AREAS: Information Systems, Materials/Processes, Sensors

ACQUISITION PROGRAM: PMA-275 - V-22 Program, ACAT I

OBJECTIVE: Design and develop an advanced, portable marking system to apply and capture images of laser bonded, machine-readable part identification codes such as DoD standard 2D barcodes. The goal is to miniaturize existing laser marking systems to facilitate the marking and reading of symbols applied to line-of-sight accessible components installed on aircraft.

DESCRIPTION: One of the cornerstones to achieve the Navy�s goal of affordable readiness is the Structural Health and Usage Monitoring (SHUM) program, an initiative to leverage existing and emerging technologies to manage and maximize the structural life of the fleet, from aircraft down to the component level. A key element of this program is to further develop means to safely apply machine-readable part identification symbols markings to parts already installed in the aircraft. The proposed laser marking system should be self-contained and incorporate all of the hardware and software elements required to generate, apply, read, and verify the mark. After reading, mark data should be stored for subsequent transfer to remote computer database(s). Focus should be placed on portability and minimizing fixturing so the system could be used in austere maintenance environments. All of the marking system components be miniaturized and integrated into a kit that can be easily carried by the technician and hardened to military standards. The basis components of the system are: A laser marker with mark positioning system, computer with data entry keyboard, system control, mark quality verification and symbol decoding software, high resolution optical reader, and power source.

Current efforts of the marking industry have been focused on developing systems to apply markings to parts during the manufacturing process. This effort is greatly hampered due to characteristics of laser marking systems designed for the manufacturing environment. The problems with implementing current laser marking systems in the field include: Need for latest engineering drawings and specification, approved marking parameters for parts to be marked, appropriate clamping fixtures, size of the laser marking system, quality, safety and engineering personnel on site to certify and monitor marking operations, procedures established to evaluate and disposition improperly applied markings, and procedures established to assess the accumulative effects of multiple marking, removals and re-applications.

This effort should initially focus on rotorcraft dynamic components such as swashplates, rotor hub components, actuators, and rotor blade components. These parts offer the greatest challenge for a marking system. Once the challenge is met for these components, the system should be capable of widespread use on many other line-of-sight accessible airframe structural components.

PHASE I: Develop and propose a conceptual design for development and test in Phase II. The first design considerations for the phase I concept is the capability for reading and laser bonding 2D marks on flat surfaces, tight radii, and compound curvatures. Secondly, the phase I concept should consider capability to read 2D marks via line-of-sight from the greatest distance possible and from oblique angles (i.e. a maintainer standing on the ground, aiming the device to read marks on a rotor hub). Finally, Consider all components that will be required for a complete, stand-alone portable laser marking/reading kit. Define size and portability goals of a final design and support with data showing appropriate technology readiness levels. Proof of concept demonstration may be conducted if time permits. Design of the system should include consideration for the application of custom format 2D marks, such as optical strain gages for Navy flight test use.

PHASE II: Develop, demonstrate and validate a working prototype of the system. Determine a complete range of geometries that require marking and survey the amount of access that is available in areas requiring in-situ marking. Travel may be conducted to the NAVAIR facilities to analyze conditions for rotorcraft maintenance as well as survey part accessibility on actual Navy/Marine Corp helicopters. Systems will be validated under conditions representative of austere maintenance environments and refinements may be made to the system as necessary. The system�s marking capabilities should be qualified by applying a selected number of marks, both 2D barcode and optical strain gage, to a test bed rotorcraft. After final validation of the system, develop a final stand alone kit to include everything necessary for laser bonding and reading in the field. This kit should consider all necessary procedures for operating the laser bonding/reading system.

PHASE III: Finalize design and configuration of the production kit. Deliver a production version of the system with appropriate durability and hardening for in service use. Include appropriate training and documentation for end users.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The developed technology will directly transition to the other military services and commercial rotary and fixed-wing aircraft industry, providing a means to extend UID tracking and a life prediction data gathering tool for aircraft components. This technology can be applied to metal assets that require a very durable mark that doesn't impact the parent materials structural properties.

REFERENCES:
1. Maley, S., Plets, J., Phan, N.D., "US Navy Roadmap to Structural Health and Usage Monitoring � The Present and Future" Presented at the American Helicopter Society 63rd Annual Forum, Virginia Beach, VA, May 1-3, 2007, www.vtol.org

2. DFARS 211.274: Item Identification and Valuation; http://farsite.hill.af.mil/reghtml/regs/far2afmcfars/fardfars/dfars/dfars211.htm

3. Unique Identification (UID), Capturing Business Intelligence Through Technology; http://www.uniqueid.org

KEYWORDS: barcode; laser; optical; mark; portable; identification

TPOC: (301)342-8511
2nd TPOC: (301)342-8267

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between November 13 and December 9, 2007, you may talk directly with the Topic Author(s) to ask technical questions about the topics. Their contact information is listed above. For reasons of competitive fairness, direct communication between proposers and topic authors is not allowed starting December 10, 2007, when DoD begins accepting proposals for this solicitation.

However, proposers may still submit written questions about solicitation topics through the DoD's SBIR/STTR Interactive Topic Information System (SITIS), in which the questioner and respondent remain anonymous and all questions and answers are posted electronically for general viewing until the solicitation closes. All proposers are advised to monitor SITIS (08.1 Q&A) during the solicitation period for questions and answers, and other significant information, relevant to the SBIR 08.1 topic under which they are proposing.

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