F-35 EOTS Focal Plane Array Batch Manufacturing and Automated Dewar Test Station Process Improvements

A2820 — Electro-Optical Targeting System (EOTS) Integrated Dewar Cooler Producibility Improvements for F-35 Lightning II

Objective

The EOTS is a high-performance, lightweight, multifunctional system for precise air-
to-air and air-to-surface targeting. Production of the EOTS focal plane array sensing
element and the integrated dewar-cooler had initially suffered from inefficiencies
and were unable to meet production quantities at the required cost points when
the EOTS multiple-phase producibility effort was initiated. Since the producibility
program’s inception, significant improvements have been made to meet production
quantities at the required cost points. Leveraging the success achieved in the previous
phases of the F-35 Lightning II EOTS producibility projects, this Electro-Optics
Center (EOC) project continues to execute cost and risk reductions for key EOTS
infrared components critical to production quantity delivery and cost success.

Payoff

The current focal plane array manufacturing process is very labor intensive and not
very efficient. Implementing new novel processes will allow for a process with 100
percent A-grade die. Insertion of a focal plane array batch manufacturing process
will significantly lower manufacturing costs (reduction in focal plane array touch
time per unit).
The current EOTS dewar process line has an in-process image screen test prior to the
final weld to verify that all electrical connections are secure and the focal plane array
is free of defects. Implementing an automated continuity test station provides the
following benefits:

• significant touch time reduction
• significant reduction in cost of rework (~80 percent reduction)
• increased capacity and throughput (~2x)
• identifying defects at this point saves ~ three weeks of manufacturing time
• increased test detail and analysis capacity
• reduced test station clean room footprint (50 percent reduction)

Together, these tasks are expected to save over $19M for the F-35 Lightning II
Program.

Implementation

The F-35 Lightning II EOTS is the transition platform. These
producibility improvements will follow a rolling implementation process –
processes will be implemented as they are completed, qualified, approved, and
cut into production prior to completion of this project. These manufacturing
process-level changes are required to be reviewed and approved by the internal
Santa Barbara Focalplane Process Control Review Board. This EOC project
has implemented multiple industry-approved process changes in calendar year
2021 impacting Lots 14 and beyond. This project is also of interest to the Air
Force Research Laboratory.