Precision Epoxy Injection System

The Challenge

An aerospace subcontractor required a robust process for injecting thick epoxy into a less than 0.010" gap between several sizes of ferrules and tube sets. After injection, the excess epoxy was removed to form a smooth fillet. The epoxy took 8 hours to cure and the ferrule/tube sets must be held rigidly during this time. After curing, the epoxy must be free of voids, or the entire assembly will be scrapped.

The Solution

Creative Automation designed and built a system to precisely hold the ferrule and tube sets concentric while injecting epoxy into the gap. The system consisted of a holding fixture that held tooling for each size of ferrule/tube sets rigidly, maintaining the parts relationship during the curing process.