University of California, San Diego
Department of Mechanical and Aerospace Engineering
Sponsored by Hi Tech Honeycomb
Sophia Davila | Rohan Shah
Parth Jha | Lucca Frey
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Project Description
This project, developed in collaboration with Hi Tech Honeycomb, focuses on automating the tack welding process for aerospace honeycomb rings. Currently performed manually, the process is slow, repetitive, and physically demanding for workers. Our solution is a modular multi-tip resistance welding system designed to improve speed, consistency, and operator comfort—without compromising the weld quality critical for aerospace applications. By integrating custom welding heads, a new alignment table, and a foot-pedal actuation system, we successfully demonstrated a dual-tip prototype capable of delivering reliable welds. This proof of concept paves the way for a fully automated system ready for real-world integration.
This project, developed in collaboration with Hi Tech Honeycomb, focuses on automating the tack welding process for aerospace honeycomb rings. Currently performed manually, the process is slow, repetitive, and physically demanding for workers. Our solution is a modular multi-tip resistance welding system designed to improve speed, consistency, and operator comfort—without compromising the weld quality critical for aerospace applications. By integrating custom welding heads, a new alignment table, and a foot-pedal actuation system, we successfully demonstrated a dual-tip prototype capable of delivering reliable welds. This proof of concept paves the way for a fully automated system ready for real-world integration.
Figure 1. Welding Table Design
Project Background and Objective
The current Tack Welding process in honeycomb ring manufacturing at Hi Tech Honeycomb is highly inefficient due to its reliance on manual operation, leading to inconsistencies, slow production rates, and increased labor costs. To address these challenges, our team has developed an automated tack welding system that enhances precision, consistency, and efficiency. By eliminating manual variability, this system aims to improve weld quality, reduce production time, and streamline the manufacturing process.
Figure 2. Current Manual Tack Welding process at HTH
Description of Design Solution
Our automated tack welding system consists of four major components: the multi-tip electrode, the welding power supply connector, the spring loaded tip holder, and the actuator. The multi-tip electrode enables multiple simultaneous welds with high alignment precision, thanks to a press-fit copper block system. The welding table ensures consistent tip alignment and easy integration with the actuation system. The foot-pedal mechanism, powered by a stepper motor and lead screw, replicates the tweezing motion while minimizing operator fatigue. Together, these subsystems deliver faster, more consistent welds while being compatible with Hi Tech Honeycomb’s existing welding power supplies.
Performance Results
Performance Results
Using the Welding Table, we were able to get 83% high quality welds - a number that is bound to increase with proper tuning of the springs and the energy supplied by the welding power supply.
Additionally, after a careful analysis of the costs associated with the Welding Table and the current manual tack welding process we estimated an annual savings of 37,000 USD for Hi Tech Honeycomb. The details of the results can be found in our Final Report.
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