The Unmanned Combat Air Vehicle (UCAV) program is an Advanced Technology Demonstration Program funded by DARPA and the Air Force. As a part of the program two demonstration air vehicles were fabricated and assembled for flight test and for demonstrating the affordability of UCAVs. Using advanced design and manufacturing toolsets, the first vehicle, 27 feet long with a 34-foot wingspan, was designed and delivered in 18 months. In addition, unique fabrication, tooling, and assembly techniques were used to produce these vehicles. This presentation will discuss the techniques used that led to the success of the program.

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