720644Advanced Tooling Technology for the Aerospace Fastener IndustryClosedGRD Development of PrototypeInnovate UKAircraft Fasteners (AFs – e.g. crucifix screw head recess and other styles) secure an array of mechanical aircraft components; a Boeing 787 comprises 40K AFs. AF punches are manufactured by ‘hobbing’ whereby the master hob carries a recess similar to the final AF recess and are driven at high pressures 250 tonnes+ into a punch blank made of M2 or M42 material. Current punches can form on average 10K AFs then scrapped due to recess and identification character wear. Tool replacement takes 30-50 minutes at a considerable downtime/scrap material cost. Punch demand is increasing as’ Low Cost Carriers will have ordered 3,300 new aircraft by 2030’. The global market for punch tooling is dominated by two US players: (1) Mairoll Inc (40%); and (2) Wrentham Tool Group (20%). Others have 25% market share whilst aerospace tool rooms have 15%. The total worldwide fastener market is valued at £55 billion. Aerospace market is split into aircraft assembly and refurbishment, and further into civil and military. A problem exists in the AF industry. The manufacturing process to create a single (or set of) master hob(s) is not cost or time effective due to:(1) use of hardened materials; (2) slow machining; (3) tight tolerances; (4) superior surface finish (5) high scrap levels. AF manufacturers are finding it uneconomic to tender for aircraft refurbishment contracts due to tooling costs. A further issue is that the life expectancy of current punches is compromised since modern aircraft employ harder material fasteners. A period of R&D will allow for the design and development of a novel process for producing AF punches to aerospace tolerances and superior geometrical form. Benefits will be (1) cheaper and long life-span punches; (2) quick manufacturing turn-around; (3) to create punches from materials other than high speed steel; and (4) significantly reduced wear failure significantly increasing AF production.