Drill template tool with integral seal

A drilling system for an aircraft structure having an outside mold line surface specified using CAD electronic data files of the CAD engineering solid model, the system comprising:

• a drill template tool with an integral seal comprising:
• a vacuum housing having a contact surface integral with and formed of the same material as the vacuum housing, wherein the contact surface has a form of an exact fit to the outside mold line surface of the structure at the contact surface whether or not in contact with the structure, the vacuum housing having a first side skirt with a plurality of holes along a length of a side of the vacuum housing, the first side skirt configured for connection to another vacuum housing;
• at least one drill bushing extending through the vacuum housing from a top surface of the vacuum housing to a bottom surface of the vacuum housing;
• at least one vacuum hose fitting integral to the vacuum housing, wherein the vacuum housing and the vacuum hose fitting are integrally fabricated;
• a plurality of attachment elements inserted through the vacuum housing attaching the drill template tool to the structure;
• and,
• an integral seal inserted in a continuous groove portion located within the bottom surface of the vacuum housing, wherein the integral seal has an outer surface in contact with the aircraft structure and has an inner surface in contact with both a portion of the bottom surface of the vacuum housing and an interior of the groove portion.

A drill template tool with a gasket for a structure having an outside mold line surface, the drill template tool with the gasket comprising:

• a vacuum housing having a contact surface integral with and formed of the same material as the vacuum housing, wherein the contact surface has a form of an exact fit to the outside mold line surface of the structure at the contact surface whether or not in contact with the structure, the vacuum housing having a first side skirt with a plurality of holes along a length of a side of the vacuum housing, the first side skirt configured for connection to another vacuum housing;
• at least one drill bushing extending through the vacuum housing from a top surface of the vacuum housing to a bottom surface of the vacuum housing;
• the gasket having an inner surface in contact with both a portion of the bottom surface of the vacuum housing and an interior portion of a continuous groove located within a bottom surface of the vacuum housing of the drill template tool and having an outer surface in contact with the structure, the gasket surrounding a plurality of holes formed in the bottom surface to accommodate drill bushings;
• and,
• a plurality of attachment elements inserted through the vacuum housing attaching the drill template tool to the structure;
• wherein the gasket is compression fitted into the continuous groove prevents leakage of fluids and debris generated by a drilling process of the structure.

A method for drilling holes in a structure using a drill template tool with an integral seal, the method comprising:

• providing a drill template tool with an integral seal comprising:
• a vacuum housing having a contact surface integral with and formed of the same material as the vacuum housing, wherein the vacuum housing and the contact surface are built directly from a precise definition for an outside mold line surface of the structure using one of selective laser sintering, fused deposition modeling, or stereolithography, so that the vacuum housing contact surface has a form of an exact fit to the outside mold line surface of the structure at the contact surface whether or not in contact with the structure, the vacuum housing having a first side skirt with a plurality of holes along a length of a side of the vacuum housing, the first side skirt configured for connection to another vacuum housing;
• at least one drill bushing extending through the vacuum housing from a top surface of the vacuum housing to a bottom surface of the vacuum housing;
• and,
• an integral seal inserted in a continuous groove portion located within the bottom surface of the vacuum housing and surrounding a plurality of holes formed in the bottom surface to accommodate drill bushings;
• securing the drill template tool with the integral seal to a surface of the structure with a plurality of attachment elements, the integral seal having an outer surface in contact with the surface of the structure and having an inner surface in contact with both a portion of the bottom surface of the vacuum housing and an interior of the groove portion;
• attaching a vacuum fitting to the drill template tool with the integral seal;
• supplying a vacuum pressure to the drill template tool with the integral seal;
• drilling holes in the structure with a drill;
• containing with the integral seal any fluids and debris generated by the drilling;
• and,
• removing the contained fluids and debris.