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The Raytheon Hawker Horizon is a state-of-the art midsize business jet now entering production. The Horizon carbon fiber composite 84-inch diameter fuselage is manufactured as three sections utilizing a seven-axis fiber placement system, and assembled in the Fuselage Align and Splice Tool (FAST). The empennage is attached to the fuselage at this station as well. This assembly system conserves floor space in a production facility in which several other aircraft are assembled as well as reducing flow time, and improving assembly accuracy. The technology employed for manufacture of fuselage sections is summarized and the assembly methods used for fuselage align and join are described. Assembly methods include laser-guided alignment of fuselage sections and automated drilling and bolt installation at two circumferential splice stations. Special features of the FAST system allow assessment of the finished product to an unprecedented level of detail.

Traditionally, large airframe structures have been assembled on hard tooling, a laborious unforgiving process. Beginning with the C-17, servo-assisted positioning tools have been used to enable faster fit-up, and better understanding of best fit options. Positioner technology has been used in large structure assembly for the 777, and the next-generation 737, and is now being implemented on other transport and civil aviation aircraft. While returning benefit to the airframe manufacturer in terms of improved fit-up and reduced cycle time, these systems are expensive and are not generally adaptable to change in product form or market demand. This paper provides an overview of positioner development and present status, and describes a series of options and initiatives that can make the technology less expensive, and easier to install, use, and maintain.