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Composite materials are beginning to comprise a greater percentage
of structural materials used throughout aircraft production. The
increased usage of composites has led individuals within the Air
Force community to revisit aircraft life cycle cost, LCC, models. A
series of affordability initiatives has culminated in significant
evidence over the last decade to better quantify the impact of
primarily composite structures in aircraft. The Advanced Composite
Cargo Aircraft, ACCA, a research effort sponsored by the Air Force
Research Lab, attempted to determine the impact of part size and
large scale composite components on LCC for cargo aircraft. This
research evaluates the data provided by the ACCA program and data
from aerospace industry partners to modify the existing LCC models.
This research finds that a relationship exists between relative
part count and touch labor hours for certain cost categories,
notably, design, design support, and testing. In particular, a
percentage reduction in part count drives a corresponding
percentage reduction in these select cost categories. These
findings suggest that reduction in part count filter through most
of the major cost categories during development and production. The
research findings suggest that the current LCC models require
modifications in the current cost estimating relationships to
capture these impacts.
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