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<p>This paper reviews mechanical fastening techniques for the final assembly of modern composite aircraft. Mechanical fastening is the primary joining method for composite structures, offering a high level of structural integrity and joint quality. Aircraft composite materials, mostly carbon fiber reinforced polymer (CFRP) composites, are pre-drilled and fastened with rivets, lockbolts, blind bolts, and especially pin systems which offer high-precision preload control and minimal hole damage. Composite aircraft’s mechanical fastening processes consist of part positioning, clamping, drilling, and fastening, and automation technologies have applied for each operation to enhance precision and repeatability. Automated systems incorporate robotic manipulators, laser trackers, flexible clamping jigs, and multifunctional end-effectors to assemble composite structures. Robotic platforms such as Electroimpact’s Flex Track and mobile robots, LISI Aerospace and KUKA’s OPTIBLIND™ and Broetje-Automation’s RACe have integrated adaptive control, force feedback, and machine vision to optimize the installation of fasteners in CFRP-metal hybrid stacks. The development of lightweight, compact end-effectors and modular robotic systems has expanded automation into the space-constrained composite aircraft assembly environment.</p>

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Mechanical Fastening Techniques in Composite Aircraft Assembly Processes: A Review

  • 期刊论文

  • 发表日期：

    2025年9月1日

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  • Dave Kim,
  • Chris Miskell,
  • Seong Hyeon Kim,
  • Sangrok Jin,
  • Sang Hwan Cho,
  • Dohoon Shin,
  • Tae-Gon Kim

摘要

This paper reviews mechanical fastening techniques for the final assembly of modern composite aircraft. Mechanical fastening is the primary joining method for composite structures, offering a high level of structural integrity and joint quality. Aircraft composite materials, mostly carbon fiber reinforced polymer (CFRP) composites, are pre-drilled and fastened with rivets, lockbolts, blind bolts, and especially pin systems which offer high-precision preload control and minimal hole damage. Composite aircraft’s mechanical fastening processes consist of part positioning, clamping, drilling, and fastening, and automation technologies have applied for each operation to enhance precision and repeatability. Automated systems incorporate robotic manipulators, laser trackers, flexible clamping jigs, and multifunctional end-effectors to assemble composite structures. Robotic platforms such as Electroimpact’s Flex Track and mobile robots, LISI Aerospace and KUKA’s OPTIBLIND™ and Broetje-Automation’s RACe have integrated adaptive control, force feedback, and machine vision to optimize the installation of fasteners in CFRP-metal hybrid stacks. The development of lightweight, compact end-effectors and modular robotic systems has expanded automation into the space-constrained composite aircraft assembly environment.