Development & Manufacturing of X-73 Space Plane Flaperons & Ruddervators

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Since 2004, LX3 Tooling Corporation has been involved in the process development and manufacturing of Boeing's X-73 space plane flaperons and ruddervators. These components are used as control surfaces for X-73 space plane models. The program was originally started by NASA, and was then transferred to the Defense Advanced Research Projects Agency (DARPA). LX3 Tooling Corporation was subcontracted by Carbon Carbon Advanced Technologies (C-CAT) to work on this project.

Our areas of involvement for this program include:

Design and manufacturing of composite layup tooling for various components, ranging from Ren tooling board to 6061 aluminum parts.
Manufacturing of assembly fixtures and tools.
Design and manufacturing of machining fixtures.
Machining program development for all carbon components.
CNC machining and inspection of all carbon components.

X-73 Space Plane Flaperons - 3D SolidWorks CAD Drawing

X-73 Space Plane Flaperons

All assemblies and fixtures were constructed from carbon and carbon composites with an outer ceramic conversion coating. These materials were chosen for their amazing durability under high-temperature conditions, as the materials for these parts need to survive the excessive heat endured when re-entering Earth's atmosphere from outer space.

LX3 is still involved in this ongoing project, supplying components that are in current use on DQ4 (4th flight unit) space planes.

Development & Manufacturing of X-73 Space Plane Flaperons & Ruddervators Project Highlights

Product Description

LX3 Tooling Corporation manufactured these Flaperons an Ruddervators for the X-73 Space Plane.

Capabilities Applied/Processes

Product Development

Design
- Composite Layup Tooling
- Machining Fixtures
Developed machining strategies for all carbon/carbon components to greatly improve assembly tolerance.
Solid Modeling (Solidworks)
Part & Material Sourcing
Supporting Documentation
- Solid Models
- Inspection Reports

Manufacturing

Manufactured Composite Layup Tooling
Manufactured Graphite Restraints
Manufactured Machining Fixtures
Manufactured Assembly Tooling
CAM Programming (Surfcam)
CNC Machining of all carbon/carbon parts

Inspection

Equipment Used to Manufacture Flaperons & Ruddervators

CNC Mill
CNC Lathe

Tightest Tolerances

± .0003"

Material Used

Composite Layup Tooling:
Ren Tooling Board
6061 Aluminum

Machining Fixtures and Assembly Tooling:
6061 Aluminum
Tool steel

Finish

Ceramic Conversion Coating

Developed to Survive High Temperatures of Re-Entry

Coating is not Applied by LX3

In process testing/inspection performed

CMM and Dimensional Inspection of all Tooling & Components

Manufacturing Turn Around Time

Ongoing Project
Currently on DQ4 (4th Flight Unit)

Industry for Use

Aerospace
Space Exploration

Standards Met

CCAT Dimensional Tolerance Requirements

Delivery Location

Arlington, Texas

Product Name

X-73 Space Plane Flaperon and Ruddervator Assemblies