The Boeing Company
Systems and methods for making and using a fitted cap for applying a shaped sealant shroud to a portion of a fastener

Abstract:

A system (200) for making a fitted cap (300) comprises a fastener template (202), dimensionally identical to a portion (106) of a fastener (100) and extending from a support plate (210), and a first plurality of through-openings (212) penetrating the support plate (210) and arranged about the fastener template (202). The system (200) also comprises a precursor cap (320) that is geometrically complementary to the fastener template (202), first means (217) for heating a first polymer sheet (270), and second means (219) for applying suction to the first polymer sheet (270) through the first plurality of through-openings (212) to vacuum-form the first polymer sheet (270) over the precursor cap (320). After vacuum-forming the first polymer sheet (270) over the precursor cap (320), at least a portion of the first polymer sheet (270) forms the fitted cap (300). The fitted cap (300) is configured to apply a shaped sealant shroud (590) to the portion (106) of the fastener (100).