PMA Boeing 757 Leading Edge Slat Skins for American Airlines.

1. Alliance Aerospace Engineering

2. PROCESS
 Scanning 2 complete aircraft leading edge slat
skins on the 757 aircraft at the American
Airlines located in Tulsa, OK.
 Scan one complete set of leading edge slat skins
from American Airlines inventory.
Alliance Aerospace Engineering

3. This system quickly brings physical parts into a
digital domain with hand laser scanners that
combine instant tracking performance with
high speed, non-contact surface scanning.
Key Features:
 Instant Tracking of difficult geometries from
multiple angles.
 Compact/Lightweight Scanner to reduce
operator fatigue.
 Large Measurement Volume to scan larger
scale parts in single setup.
 Measure difficult textures without powder or
sprays, including mirror finishes.
Alliance Aerospace Engineering

4.  SCANTRAK hand held laser
scanner is lightweight,
beamless, and has no
mechanical restrictions.
Provides unlimited range Polyworks modeler is a
of motion for comprehensive modeling software
uninterrupted scanning. that enables a total
interoperability between point
cloud scanning equipment and
surface modeling.
 Multi-Sided Probe (MSP)
tracks, measures, and  Includes best fit alignment of
scans with unlimited range individual scan sessions or
multiple scans into a single model.
of motion and no off-angle
limitations.  Enables correcting imperfect
digitized geometry using flat and
curvature based hole filling,
boundary reconstruction, sharp
 Dynamic Referencing Kit edge and corner reconstruction.
provides vibration
compensation and
automatic alignment.
Alliance Aerospace Engineering

5.  Every morning, prior to scan, equipment must be calibrated. After letting the optics warm up
for 30-45 minutes, the MSP was calibrated. This allows the system to calibrate as to the
orientation of the scanner.
 After this, we calibrate how the Optical Tracker calculates the distance and location using a program
called auto-scale. Using the previously calibrated MSP, we measure a certified 1000mm bar in different
positions.
 Finally, we calibrate the laser scanner using a known sphere. This calibrates how the cameras in the
scanner head calculate distance based off the projected laser line.
Alliance Aerospace Engineering

6.  The task of getting all the equipment setup in preparation of scanning, was lengthy and took a
large planning effort. The true challenge was figuring the correct setup to scan up to 25 feet in
the air.
 First step was to setup the tracker on one Skyjack and the computer and scanner on the second
Skyjack. (As shown above)
Alliance Aerospace Engineering

7. Second, the Skyjacks were positioned
in such a way that the tracker would
be able to see the entire part while
allowing the persons canning to reach
all aspect without disturbing the line
of sight between the tracker and the
scanner. This setup was variable from
slat to slat.
The 5 and 6 slats provided an
additional challenge for Skyjack
positioning, as space is limited
between the engine and the
fuselage.
Alliance Aerospace Engineering

8.  Thirdly, the ping pong balls and Dynamic
Part Reference diodes were applied using
hot glue. The ping pong balls allowed us
to scan the part in two sections without
putting excessive stress on the computer
during data acquisition. The DPR diodes
create a coordinate system that is locked
to the part in case the slat tracker is
moved.
Alliance Aerospace Engineering

9.  Now that all is calibrated and setup, the scan may begin. The scanner provides a visual
viewfinder and audible tone bursts so you can keep the scanner optimal difference from
the part.
 Additionally, the computer provides real-time views of the scan data in relation to other
data.
Alliance Aerospace Engineering

10.  The Polyworks Software
scans each pass in a
different color. This allows
you to see in real-time how
your data is overlapping
and what areas are missing.
You may also see below the
areas that still need to be
scanned.
 From the scanned data, we then create
a high quality mesh and build simple,
dimension-able, geometry for our
model based definition and drawings.
Alliance Aerospace Engineering

11.  At this point, a fully usable, PMA worthy part is manufactured for the
customer. By creating forming tools and machine fixtures, these parts
can be produced at high quantities while maintaining 100% quality
and accuracy.
10-N30331 form tool and the Alliance Aerospace part
during conformity.
Alliance Aerospace Parts Complete post manufacture.
Alliance Aerospace Engineering

12. Alliance Aerospace Engineering

13. Contact Info
Contact Info
Address: 185 Paularino Ave. Suite A
Costa Mesa, California USA 92626
 Phone: (714) 760-9913
 Email: info@allianceaeroeng.com
Alliance Aerospace Engineering