1 October 2013 www.aeromag.com www.aero-mag.com THE EUROPEAN MAGAZINE FOR A GLOBAL INDUSTRY CIVIL & DEFENCE/SPACE/SUPPLY CHAIN NOVEMBER 2023 ADVANCED MATERIALS SCULPTING NEW POSSIBILITIES Page 10
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Changing with the times Editor | Mike Richardson | newsdesk@aero-mag.com | Tel: +44 (0) 1634 825709 Deputy Editor | Ed Hill | ehill@mitpublishing.co.uk | Tel: +44 (0) 1634 825705 Digital content coordinator | Michael Tyrrell | mtyrrell@mitpublishing.co.uk Tel: +44 (0) 1634 825713 Sales Manager | David McCauley dmc@aero-mag.com | Tel: +44 (0)7557 308369 Sales Director | Andy Morley amorley@aero-mag.com | Tel: +44 (0) 1634 825701 Art Editor | Sarah Blake sarahblake@sablemedia.co.uk | Tel: +44 (0) 1233 770781 Production Coordinator| Ewa Hodden ehodden@mitpublishing.co.uk | Tel: +44 (0) 1634 825703 Circulation, Subscriptions and Database Research | Perception SAS aero@mitpublishing.com | Tel: +44 (0) 1825 701520 Financial Controller | Valerie Prentice | accounts@mitpublishing.co.uk Publisher | Liam McCauley Director | David Rose Published by | MIT Publishing Limited | Featherstone House | 375 High Street | Rochester | Kent ME1 1DA | United Kingdom | Tel: +44 (0) 1634 830566 Published 10 times a year, Aerospace Manufacturing is distributed free of charge to applicants in the UK and certain other countries who meet the publishers criteria. Subscriptions are also available at £150 per annum which represents a 40% saving on the single issue price. While every care is taken to provide accurate information, the publishers cannot accept liability for errors or omissions, no matter how they may arise. Authors opinions do not necessarily reflect those of the publisher. All rights reserved. No part of this publication may be reproduced or transmitted without the consent of the publisher. Copyright: MIT Publishing Ltd 2023 Printed by: Pureprint Group 4 NEWS ADVANCED MATERIALS 10 Sculpting new possibilities – Additive manufacturing 14 AM: making aerospace more sustainable – Additive manufacturing 16 Tactile, digitised insight into surface inspection – Test & measurement 18 Spread your wings – Machine tools SPECIAL REPORT 20 Taking robotics to higher heights – Automation 22 Clean connections – Component cleaning 24 Accelerate inspection in an instant – Quality & inspection 25 Find parts – fast! – MRO DIGITAL MANUFACTURING 26 People, process, principle – Simulation 28 What lies ahead for digitalisation? – CAD/CAM FINAL APPROACH 30 Here, there – and everywhere! – Alan Fisher, CEO of the Farnborough Aerospace Consortium Next issue: Events: Southern Manufacturing, Civil aircraft, Technology feature: Engines, Materials: Composites, Machining techniques: Machine tools, Special report: Automation, Supply chain: Partnerships, Digital manufacturing: Industry 4.0, Final approach Welcome to the November issue – the last one of 2023. Well, where did the time go? I’ve been piloting Aerospace Manufacturing magazine for nigh on 15 years now and I’ve seen a lot of changes since I first strapped myself into the cockpit. None more so than with the many automation-related topics programmed into this issue. I really should consider employing a robot to produce the magazine for me whilst I simply dictate all the words to it! In this issue, we hear how Siemens’ CNC control systems help factory automation specialist, Electroimpact create an industrial, fibre-reinforced 3D printer that enables tool-less rapid fabrication of aerospace-grade integrated composite structures. On a similar theme, FANUC explains how its CNC controls can control the multiple axes of large, automated fibre lay-up machines to satisfy our industry’s need for more automated manufacturing techniques with composite materials. Fortunately, robots would appear to be well-suited to handling this challenge. Never in need of a coffee break, unlikely to catch a cold and even less likely to be spotted on the picket line in the event of a union dispute, automated processes are increasingly being employed to perform tasks such as drilling, fastening, riveting, welding, spray painting and tape layup processes. The naysayers will claim that automation diminishes the job prospects of people trying to enter the manufacturing industry. They’ve got a point; just how many more jobs will there be on the shopfloors of tomorrow? Glued almost ‘man-machine interface’ like to their gaming consoles and smart phones, the younger generation would appear naturally inclined to joining the next wave of automated system programmers. The manufacturing industry is certainly changing. When it comes to physical or mental labour: anything humans can do, robots – increasingly enabled by Artificial Intelligence – can do it better! Mike Richardson, editor ISSN 2056-3434 www.aero-mag.com Aerospace Manufacturing November 2023 3 COMMENT & CONTENTS Volume 18 Issue 171
4 October 2013 www.aeromag.com NEWS November 2023 Aerospace Manufacturing www.aero-mag.com Carter joins hydrogen project Carter Manufacturing has announced its participation in the Future Engine Technology for the Control of Hydrogen (FETCH) project. The collaboration, led by Moog Aircraft in the UK is focused on the development of the key technologies required to exploit the benefits of future aircraft hydrogen fuel systems. Carter Manufacturing’s contribution is to develop bespoke bearing solutions for liquid and gaseous hydrogen. This is based on the company’s experience in developing bearings for cryogenic applications, such as rocket propulsion, commercial industrial pump applications, along with scientific research. “We are delighted to be part of this groundbreaking collaboration, driving the development and innovation of this important sustainable aviation initiative,” stated Karl Brundell, managing director of Carter Manufacturing. “The FETCH collaboration is an excellent example of our commitment to accelerate the development of hydrogen powered aircraft and underlines our expertise in developing bearings which excel in challenging and complex hydrogen applications.” www.carterbearings.co.uk Southern Manufacturing & Electronics, which will take place in Farnborough next February, promises to be a resounding success as the stand space is filling up fast, driven in part by the highest ever number of enquiries from overseas. What started out as a small regional show in 1997 has blossomed into a major industrial exhibition of pan-European if not global significance. Combining in one place the best of what the mechanical engineering, electrical and electronics industries have to offer, the show has wide appeal thanks to the incredible range of firms taking part. There are no physical barriers between the areas, so people can walk easily between stands showing many diverse products and services. They include machinery and production equipment, automation and robotics, software, components, consumables, and an enormous range of subcontract manufacturing expertise. The show co-locates with AutoAero, an event focused on suppliers to the UK’s aerospace and automotive engineering sectors. It provides an ideal opportunity for aerospace professionals to source suppliers with skills and experience across a wide range of engineering disciplines including precision engineering, electronics, testing and certification, and advanced materials including composites. With aerospace continuing its recovery and revenues set to grow at a double-digit percentage rate year-on-year, this part of the event will undoubtedly take on ever more significance. Over the three days there will be a free technical seminar programme, giving visitors and exhibitors alike an opportunity to learn ways to address technical, managerial and environmental issues facing manufacturers today. The show will take place at the Farnborough International Exhibition & Conference Centre from 6th to 8th February and is well served by road and public transport links. A regular, free bus service runs between Farnborough’s railway stations and the showground. Parking and admission are also free of charge, with tickets already available via the organiser’s website. www.industrysouth.co.uk Southern Manufacturing off to a flyer ELE Advanced Technologies (ELE) has appointed David Stanley as its new CEO, following a period of investment and transformation. Stanley succeeds Manesh Pandya, former CEO, who, after heading up the business since 2001, is retiring and will take on the role of consultant. The change follows a period of significant investment with over £12 million invested in the business, including in its relocation to a new, larger manufacturing facility at Lomeshaye Industrial Estate, Nelson, Lancashire in 2023. Commenting on his appointment, Stanley said: “ELE has ambitious and growth-driven plans following the move to our new facility. This is a really exciting time and I’d like to thank Manesh for leading our business over the past 22 years. Looking ahead, my immediate focus is on further enhancing and building customer relationships, growing our global customer base through our offer of innovative technologies, and continuing to lead on sustainability and innovation.” https://eleat.co.uk ELE appoints new CEO
We are LAUDA Technology – the world leader in precise temperature control, and your reliable Aerospace partner. Since 1956, LAUDA has been providing constant temperature equipment and heating and cooling systems to a wide range of customers. This has grown over the years and many of our life-long customers are from a range of industries, working in; research and development, laboratories, the semiconductor industry, automotive and of course, aerospace engineering and production. Our portfolio of equipment boasts a wide range of units, all tailored to your specific needs. LAUDA’s highly-durable process circulator product range provides thermoregulation for external applications from 320°C down to as low as -90°C. An example of this is the Integral XT Circulation Thermostat - with up to 25kW of cooling power - it’s designed to meet the most stringent of customer needs, whilst providing reliable performance. The Integral XT operates in accordance to the flow principle with a cold oil blanket that enables the utilisation of temperature control during dynamic temperature control tasks. A modular interface concept that is fit for the future ensures maximum networking of user processes. In addition, all the units in the Integral range offer our new software - LAUDA.LIVE - for safe and reliable remote maintenance and monitoring. The LAUDA Proline units also provide accuracy and safety in aerospace testing. With the LAUDA Proline Kryomat’s temperature range of -90°C - 200°C, it serves as an excellent heating and cooling system in testing phases for spacecraft sub-systems. With a 3.5kW heater and up to 6kW of cooling power, these units are also used to heat and cool entire satellites. Some of LAUDA’s smaller units are used for testing and production inside the lab too – our LAUDA TD 4 Tensiometer is used in the process of aluminium etching. The role of the LAUDA TD 4 Tensiometer is to measure the surface tension of the etching solution. The aluminium then in turn, is used to manufacture aircraft wings. If you find yourself needing further specialist support, we also provide completely bespoke heating and cooling solutions - that can be tailored to meet any requirement. Want to find out more? Get in touch with our experts today to discuss your specific thermoregulation and temperature control needs. ADVERTORIAL Digital twin simulation software delivers hard benefits to CNC users info@lauda-technology.co.uk | +44 (0)1780 243 118 | www.lauda-technology.co.uk EMPOWERING EXCELLENCE. FOR A BETTER FUTURE.
6 October 2013 www.aeromag.com November 2023 Aerospace Manufacturing www.aero-mag.com NEWS Defining the detail... With over 40 years of tooling manufacture experience we continue to position ourselves at the forefront of research and development, focusing on being the very best at what we do! Visit our website for our full range of precision cutting tools. Tooling for wood, composites, metals and foam 01277 260340 sales@primatooling.co.uk www.primatooling.co.uk Follow us on: PRECISION TOOL MANUFACTURERS Carrickfergus-based injection moulding company, IPC Mouldings, has received its fifth consecutive gold performance award as part of the SC21 Operational Excellence programme. IPC Mouldings is one of only seven companies across the UK to hold the prestigious gold award standard and has been sponsored through the SC21 programme by Collins Aerospace. The Gold award was presented to the company in October at an ADS Aircraft Interiors Group Meeting, hosted by Collins Aerospace, in the Kilmorey Arms Hotel in Kilkeel. Speaking about the achievement, Joanne Liddle, managing director of IPC Mouldings said: “I am delighted that IPC Mouldings has again been recognised with the SC21 Gold performance standard award for our achievement of 99.8% delivery and 99.96% quality across all our customers’ orders during the 12-month period up to 1st June 2023.” https://ipcmouldings.com IPC Mouldings retains SC21 gold award A move into new markets and a series of contract wins have paved the way for a raft of new roles at Manchester-based EDM. The group has created 20 posts this year, with a number of these filled through internal promotions. The new arrivals also include a cohort of apprentices, who began their four-year training programme last month. EDM’s recruitment programme means its workforce has increased to 134 this year. Managing director Tony Bermingham said he was confident that EDM would perform strongly over the next 12 months, and as a result could seek to recruit up to 40 engineers and other professionals to support client projects. “All these additional revenue streams will provide opportunities for further job creation as the business continues to grow,” stated Bermingham. “We are confident that 2024 looks like being a busy year for EDM, and this could mean recruiting between 30 and 40 engineers and professionals to support ongoing projects.” www.edmgroupltd.com EDM bolsters workforce amid expansion Produmax has announced its integration with the ASG Group, a fast-growing global aerospace manufacturing conglomerate with nine locations across the UK, Germany and India and led by managing director, Simon Weston. Produmax employs around 90 people and has worked at the forefront of aerospace manufacturing for the past 25 years, led by directors, Jeremy and Mandy Ridyard. “We have been on a remarkable journey for over two decades, and this partnership allows us to further expand our reach and impact in the aerospace industry,” stated Jeremy Ridyard. “ASG Group’s value of engineering excellence align perfectly with ours, and together, we are well-equipped to take on new opportunities. Our goal together, is to drive this business to in excess of £20m over the next five years.” Mandy Ridyard added: “Our people, have always been our greatest asset. This merger means we can offer even more exciting career prospects, whilst continuing to focus on diversity and empowerment in our workplace. We remain committed to nurturing and developing talent. Working together makes so much sense to take advantage of the opportunities the aerospace industry now presents.” www.produmax.co.uk Produmax joins forces with ASG Group
Boeing Sheffield celebrates fifth anniversary Boeing is celebrating the fifth anniversary of its Sheffield-based site, the company’s first European manufacturing facility. Over the past five years, Boeing Sheffield has shipped more than 21,000 UK-made parts supporting the production of the 737 aircraft. The 6,200m2 facility represents an investment of £40 million and continues to play a pivotal role in Boeing’s global advanced manufacturing ecosystem. Employees at the South Yorkshire site use advanced manufacturing techniques to make the trailing edge actuator components for the 737 family, including the P-8 Poseidon and the E-7 Wedgetail aircraft. Actuator components help control wing flaps during take-off and landing. “As we celebrate reaching this milestone, we are reminded of the incredible journey we have undertaken together with our partners and the local community,” said Maria Laine, president of Boeing in the UK, Ireland and the Nordics. “I would particularly like to thank our fantastic Boeing Sheffield team for everything they’ve achieved. The enduring relationships we’ve built in the local area have been integral to our ability to deliver worldclass products to our customers worldwide.” Boeing’s long-standing history in Sheffield began in 2001, as a co-founder of the University of Sheffield Advanced Manufacturing Research Centre (AMRC). www.boeing.co.uk Denroy celebrates DSEI showing The Denroy team has been reflecting on what was a hugely successful exhibition at DSEI 2023, ExCeL London last September. The company showcased its wealth of experience and expertise it has in supplying parts for the defence sector. The company has been supplying the defence sector for many years and prides itself on holding SC21 accreditation for six consecutive years. “We were delighted to be exhibiting at DSEI 2023, which is the most significant defence exhibition in the UK,” stated Denroy chief commercial officer, Gareth Deering. “As the world’s leading innovator in the design and manufacture of engineered polymer components and solutions, Denroy is perfectly positioned to ensure operational excellence in high quality, lightweight, military grade parts.” https://denroy.com
Get in touch: 01189 795 200 | saleseu@kyocera-sgstool.com | kyocera-sgstool.co.uk High Performance Cutting Tools for Machining Challenges Keeping the world moving Over 600 national and international suppliers come together to exhibit at Farnborough International Exhibition and Conference Centre this February for Southern Manufacturing and Electronics (inc AutoAero) 2024. Meet the power behind UK manufacturing industry and see live demonstrations and new product launches of machine tools & tooling, electronics, factory & process automation, packaging & handling, labelling & marking, 3D print technology, test & measurement, materials, composites & adhesives, rapid prototyping, ICT, drives & controls, plastics & polymers and laboratory equipment. Free industry seminar programme online @ www.industrysouth.co.uk The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 6th February. 6th - 8th February 9.30am - 4.30pm FARNBOROUGH | Hants | GU14 6TQ (3.30pm close Thurs) Where Industry and Innovation converge FREE SEMINARS FREE PARKING Incorporating The Subcontract Engineering Exhibition PRE-REGISTER TODAY www.industrysouth.co.uk for your Fast Track Entry Badge, Preview Magazine and Event Catalogue SOUTHERN MANUFACTURING & ELECTRONICS is an ETES event organised by European Trade & Exhibition Services Ltd 01784 880890 | philv@etes.co.uk SM&E24_AD_PES-CiM_2023-24_180Wx130H_ADVERT.qxp_12092023 12/09/2023 17:35 Page 1
Aerospace Manufacturing November 2023 9 NEWS In response to significant growth in demand for bespoke aircraft interior refurbishment projects, Starling Aerospace has extended its design and manufacturing capability, thanks to a six figure investment. The aircraft interiors specialist has become the first and only UK aerospace company to operate a 3-in-1 CNC perforating, stitching and embroidery combined machine. Additionally, Starling has upgraded its sewing shop with the installation of six fully automated Juki sewing machines. The recent commissioning of its first in-house autoclave also builds on Starling’s fully integrated expertise, by facilitating the fabrication of interior panels, fixtures and fittings, from prepreg carbon fibre. Using this reinforced material, which is pre-impregnated with a resin system and curing agent, results in the manufacture of superior strength and lighter weight products, to a consistently high finish. According to Starling’s co-founding director, Coralie Wigg, the company’s advancement on multiple fronts will enable it to offer a market-leading design and production service for any aircraft interior. “This major investment in machinery represents the biggest upgrade in Starling’s capability since the company was established more than two decades ago,” she stated. “By combining different sewing tasks into a single CNC machine, we can create any design for leather and fabric, no matter how complex. Equally, our in-house autoclave provides an agile solution for customers needing a fast project turnaround.” www.starlingaerospace.co.uk Starling expands interiors capacity FLEXIBLE DEBURRING OF AIRCRAFT PARTS - also composite parts Automatic and manual solutions Fladder Danmark A/S Tel. +45 75297133 Mail: fladder@fladder.dk www.fladder.com Contact us for a test The Manufacturing Technologies Association (MTA) will use its flagship event, MACH 2024, to launch its new initiative to help UK manufacturers become more competitive while improving efficiency and sustainability. A series of Knowledge Hubs will feature at the event being held at the NEC, Birmingham from 15-19 April 2024, designed to encourage UK engineeringbased manufacturers to adopt new technology and techniques to enable them to compete globally in a sustainable manner. The MTA’s Knowledge Hubs will focus on educating users in when and how to adopt new technologies such as automation and robotics, data and AI for manufacturing, Sustainable manufacturing towards net zero and the use of additive manufacturing techniques. “Our Knowledge Hubs at MACH 2024 aim to reverse the decline and enable the UK to re-establish itself as a sovereign manufacturer,” stated James Selka, CEO of the MTA, which organises the MACH exhibition. “To do that we have to recognise the importance of investing in the latest technologies for improving manufacturing efficiency and optimising productivity. “MACH is the UK’s only live, national event showcasing sustainable, innovative technologies used across the manufacturing spectrum and is the destination of choice for companies looking to adopt and invest in the digital revolution.” www.machexhibition.com MTA reveals MACH show knowledge initiative
10 October 2013 www.aeromag.com ADVANCED MATERIALS: ADDITIVE MANUFACTURING November 2023 Aerospace Manufacturing www.aero-mag.com erospace and defence design engineers and the complex components they develop require true manufacturing agility. Shepherding ideas from seeming impossibilities to sparks of inspiration to groundbreaking products that enable innovation can be both exhilarating and maddening. To iterate quickly and enable true collaboration, the fastest teams in engineering employ the Electroimpact SCRAM system powered by Siemens’ SINUMERIK ONE CNC. Helping to make the impossible possible, Electroimpact has integrated an in-situ out-of-autoclave thermoplastic automated fibre placement (AFP) process, an advanced fused filament fabrication (FFF) 3D printing process, a fused granulate fabrication (FGF) 3D printing process, and subtractive machining into a unified scalable composite robotic additive manufacturing (SCRAM) system. SCRAM is an industrial, true 6-axis continuous fibre-reinforced 3D printer that enables the tool-less rapid fabrication of aerospace-grade integrated composite structures. High-performance thermoplastics combined with a high percentage of continuous fibre reinforcement are used to produce parts with Powered by Siemens’ SINUMERIK ONE CNC. Aerospace Manufacturing hears how Electroimpact’s industrial, true 6-axis continuous fibre-reinforced SCRAM system 3D printer enables tool-less rapid fabrication of aerospace-grade integrated composite structures. A SCULPTING NEW POSSIBILITIES SCRAM can perform several different manufacturing technologies — all in the same cell, all in one place (above)
Renishaw UK Sales Ltd, New Mills, Wotton-under-Edge, Gloucestershire, +44 (0) 1453 524524 renishaw.uk@renishaw.com UK, GL12 8JR © 2023 Renishaw plc. All rights reserved. www.renishaw.com/revo speed • accuracy • flexibility Why compromise? speed accuracy flexibility Historically, precision measurement has required multiple devices, with speed often limited by fundamental CMM design constraints. Renishaw’s REVO® system overcomes the speed versus accuracy CMM challenge with patented 5-axis technology, and offers a range of interchangeable sensors providing tactile touch-trigger and scanning measurement; surface finish; ultrasonic thickness measurement and non-contact vision on a single CMM. REVO sets the standard for fast, accurate and flexible multi-sensor CMM measurement, without compromise.
12 October 2013 www.aeromag.com November 2023 Aerospace Manufacturing www.aero-mag.com ADVANCED MATERIALS: ADDITIVE MANUFACTURING exceptional material properties previously unheard of in the world of additive manufacturing. The enhanced performance of the 6-axis system offers unmatched dexterity and flexibility, enabling shapes, accuracies and intricacies not possible otherwise. This technology is said to have no equal in the industry and is a unique offering available only from Electroimpact. The capabilities and processing speed of the SINUMERIK ONE control empower Electroimpact engineers to achieve these breakthroughs in additive manufacturing. True 3D printing Most 3D printing processes are more accurately described as 2.5D printing. The material is deposited successively in flat slices, which when stacked together form a 3D object. In contrast, the SCRAM process renders true 3D printing. Layers of continuous fibre-reinforced thermoplastic capably take the shape of complex contours, including aerodynamic surfaces and ducts for fluid flow. As a 6-axis process, fibre orientation within each layer can be tailored to the specific application, providing optimal strength and appropriate stiffness distribution throughout the part, much like a conventional AFP system. In addition to the continuous fibrereinforced thermoplastic printing process and the FGF support tool printing process, SCRAM cells are also fitted with two FFF nozzles optimised for deposition of thermoplastic material reinforced with short or chopped fibre. A proprietary laser heating system is incorporated, producing exceptionally strong bonds between layers. This process is ideal for situations in which layering continuous fibre is geometrically impossible or otherwise does not make sense. “It allows us to deposit the material exactly where it needs to be and only where it needs to be, achieving the highest possible strength and lowest weight,” says Ryan Bischoff, senior composite engineer at Electroimpact. This is a true 3D printing process where the layers are not simply a stack of planes. Complex geometries such as variable density core and other internal structures can be printed directly onto continuous fibre-reinforced layers with widely varying curvature. If desired, additional continuous fibre-reinforced layers can then be deposited on top of the chopped fibre-reinforced core structure, forming an upper skin. The system is an integration of several additive and subtractive processes, combined with Electroimpact’s patented accurate robot, a rotating build platform and a climate-controlled build chamber. Electroimpact then supercharges everything with the SINUMERIK ONE control from Siemens. “SINUMERIK ONE allows us to run more complicated code much faster,” says Kylie Martineau, Electroimpact’s controls engineer. Bischoff adds that Electroimpact expanded from doing mostly drilling and fastening to additive manufacturing about 15 years ago: “That move and the advancements over the years led to the development of a system that we call a ‘factory in a cell.’ Instead of needing a whole assembly line, with each dedicated machine only performing a single function, it is one system, which can be printing ducts for jet engines one day and a wing component the next. It can be quickly changed and adapted according to needs.” The SCRAM enables the tool-less rapid fabrication of aerospace-grade integrated composite structures. This factory in a cell gives builders the option to produce low-run parts that make all the difference in their designs. This might be a carbon fibre element for Formula One racing or a part made from a revolutionary alloy that is destined for space. For short runs or small runs, nothing can compete with this technology. “Here is where the factory in a cell helps teams develop parts much more quickly than a traditional facility,” states Bischoff. “You complete the whole process within the SCRAM system. It makes sense because these are not the kind of parts that are produced in the thousands. “Our customers are doing extraordinary work, and we are right there alongside them. Your Electroimpact engineer is with you though the lifespan of the system for all questions and requests. We are here to help builders push boundaries. We service our equipment till the day it dies. Support is one of the things that Electroimpact does better than anyone else in the industry.” With the SCRAM system, 3D printing replaces the need for the traditional complex tooling development typically used for automated carbon-fibre layup. This eliminates the inflated cost and time investments needed in traditional tooling and development; therefore, the SCRAM system allows for faster corrections and modifications. Once the complex tooling is printed, the SINUMERIK ONE control facilitates rapid changes throughout the process. First, the SCRAM system changes to a multi-axis milling head that finishes the form to exacting specifications. Then the SCRAM system changes once again to the 6-axis carbon-fibre placement head and applies the intricate pattern of carbon fibre tape to the support material. Bischoff explains that the tape is deposited quickly, establishing the form. Next, the support material additive is then completely dissolved away, leaving behind a component in the exact shape the manufacturer needs. “The knowledge that we’re able to dissolve the tooling without creating greywater brings us great peace of mind,” he says. The SCRAM system, with the power of SINUMERIK ONE, also enables iteration. “We are working to make an open system that will support the material choices and make the parts each customer needs. We are driven by customer demand,” Bischoff explains.Electroimpact engineers appreciate the advanced features of this next-generation control platform. “The faster processor times for both motion control and PLC, combined with Ryan Bischoff of Electroimpact (above) The SCRAM system provides a true 3D printing process (below left)
Scan here for more Siemens articles new functionalities of the SINUMERIK ONE, further enable the incredible work Electroimpact is doing with the SCRAM system,” says Steve Czajkowski, engineering manager at Siemens. Siemens’ account manager, Brian Cubie agrees: “Our system is the foundation on which they are building, and it is just incredible to experience. I have been in robotics for many years, and to see what the engineers at Electroimpact are doing in terms of digitalising the factory floor is exciting. They are always at the forefront. Electroimpact does a phenomenal job of taking our new SINUMERIK ONE control and adding encoders for feedback and run it though their own kinematics.” SINUMERIK ONE is built for highspeed processing that enables the accuracy needed for specialised parts. It is ideally suited to the SCRAM’s groundbreaking ability to shift from 3D printing to finishing and continuous carbon-fibre placement, all from one control. SINUMERIK ONE makes product development faster, more flexible, and more efficient. Looking towards the future, the SINUMERIK ONE control platform will take the SCRAM into advanced digital twin technology. This will help teams engineer a fully functioning machine even before a real-life prototype exists and for teams to transfer tasks from the real world to the virtual environment. It will keep projects moving consistently to the work preparation phase. Having SINUMERIK ONE as a built-in tool will help reduce overhead costs for projects and support. “There‘s a huge industry push to having a digital twin,” Martineau says. “I am extremely excited about supporting SCRAM in our customers’ endeavours moving forward. Each customer is pushing what is possible. They are reaching for ideas that are slightly out of the ordinary. With this true digital twin, instead of needing to travel for an on-site visit or asking for photos or video footage of their challenges, the PLC will allow simulation right inside the control.” Just as customers can run the digital twin from their computer, Martineau will be able to operate the digital control of a customer’s SCRAM right from hers. “We hear from customers when they’re striving for the next level, pushing the system to the max,” she says. “Being able to jump in and see what’s happening is so valuable. “The digital twin capabilities of SINUMERIK ONE will enable us to work extremely close to our customers in the future, supporting their desires to push the envelope of product development. With digital twin technology this accurate, customers will benefit from knowing we can jump in anytime to seamlessly help troubleshoot.” Siemens and Electroimpact have been partners for more than 10 years. The SCRAM previously included the SINUMERIK 840D sl, a precision CNC control highly favoured by the aerospace industry. SINUMERIK ONE is faster and excels at more complex code. With the advancements of the SINUMERIK ONE control, the possibilities are endless. “Electroimpact is always pushing the envelope,” says Brian McMinn, head of the Siemens Machine Tool Systems business. “Their approach is to always be at the very leading edge of manufacturing technology. We are glad to be a part of their team as SINUMERIK ONE has the power and speed to make it all possible.” Expect to see further advancements from Electroimpact in the next few years that raise the bar even higher for complex aerospace design and development. www.usa.siemens.com/ei-scram Kylie Martineau, controls engineer at Electroimpact (above) Aerospace Technology Week Americas and Europe brings you the best in developments and trends in connectivity and e-enabling for airlines, the latest in regulatory, policy and technical SES and Next-Gen challenges for avionics, and the technological developments and systems that affect the design and construction of aircraft. Join us in Atlanta GA, or Munich, Germany, for the largest gathering of aerospace technology, airlines, avionics, aerospace testing, flight ops and MRO communities. GET INFORMED, GET UPDATED AND GET BETTER CONNECTED! Register online at www.aerospacetechweek.com The premier events for the aerospace technology industry • Over 1250 delegates and attendees • 200 Hosted Airlines • High Level Conferences • Technical & Technology Workshops • Certified Training • Leading showcase exhibition Avionics Connectivity Testing Flight Ops iT MRO iT AMERICAS 14-15 November ’23 | Atlanta, USA EUROPE 17-18 April ’24 | Munich, Germany
14 October 2013 www.aeromag.com ADVANCED MATERIALS: ADDITIVE MANUFACTURING November 2023 Aerospace Manufacturing www.aero-mag.com Scan here for more Trumpf articles igh-tech company, Trumpf says it is helping the aviation industry to reduce greenhouse gases. With its 3D printers and lasers, aviation companies can save a lot of weight in aircraft manufacturing and produce more efficient engines. “Laser technology and 3D printing are key technologies for manufacturing sustainable aircraft,” says Richard Bannmüller, CEO and president of Trumpf Laser and System Technology. “With technology and know-how from Trumpf, the aviation industry will be able to put electric-powered airplanes and air cabs in the air in the near future. We can support the aviation industry with our years of automotive expertise in battery and e-mobility.” At this year’s Advanced Engineering show, held at the NEC Birmingham, Trumpf emphasised its expertise in e-mobility and aerospace with special focus on applications in satellite, rocket and engine production. Emission-free flying Almost all aircraft manufacturers and suppliers are working on climatefriendly aircraft. Many are already pursuing concrete concepts for the electrification of aircraft engines. For aviation, manufacturers need to develop particularly lightweight, safe and reliable batteries and electric motors. “Our experience in manufacturing electric drives and batteries in the automotive industry can be transferred to many areas of aviation,” states Bannmüller. “With our manufacturing technology, we can make an important contribution to the decarbonisation of aviation.” Trumpf works with many OEMs and suppliers in the aerospace industry. To manufacture particularly efficient rockets and thrusters, the companies use lasers from the hightech company to cut and weld metal alloys. To make engines lighter and more efficient, the aerospace industry uses 3D printers from Trumpf. As a result, manufacturers are producing lightweight thrusters that are also particularly optimised for efficiency. “Trumpf stands by the aerospace industry as a reliable partner with its manufacturing know-how,” says Bannmüller. “The product life cycles in the aerospace industry are lengthy. Here, we support our customers for many years with service and spare parts for our machines.” The aviation industry also benefits from Trumpf technology when it comes to maintenance. For example, instead of purchasing new engine blades, aviation companies repair them using laser cladding (LMD). In this process, the laser creates a molten pool on the surface of the engine blade and precisely melts the simultaneously fed metal powder according to the desired shape. By repairing cost-intensive components, the aerospace industry can save up to 80% in costs compared to purchasing new ones. www.trumpf.com Laser technology and 3D printing are key technologies for manufacturing sustainably operable aircraft. Trumpf explains how it supports the aviation industry with its manufacturing know-how. H AM: MAKING AEROSPACE MORE SUSTAINABLE Trumpf says its 3D printing of thrusters helps reduce leadtime (left) With 3D printers and lasers, companies can save a lot of weight in aircraft manufacturing (below)
The Market Leader in Large Format Additive Manufacturing www.thermwood.com 800-533-6901 MADE IN USA Scan QR Code to view a case study between Thermwood and General Atomics. ermwood LSAM - e Broadest Line of LFAM Systems available. Systems for a wide variety of applications, materials and budgets. HLP- Horizontal Layer Printing Horizontal Layer Printing (HLP). Standard printing from the machine table. Fastest Print Heads from up to 200lbs per hour to over 500lbs per hour. 3 Printing Orientations LSAM systems can print in three positions: VLP- Vertical Layer Printing Vertical Layer Print (VLP) option. Vertical Layer Printing allows parts to be printed that are as long as the machine table. ALP- Angle Layer Printing Angle Layer Printing (ALP) option. Angle Layer Printing is the ability to print at a 45 degree angle. Used to Produce: Industrial Fixtures Molds (including high temp) Tooling Foundry Patterns Prototypes End Products LSAM1540 LSAM AP510 Print Only or Print/ Trim Combinations Available LSAM1010
16 October 2013 www.aeromag.com November 2023 Aerospace Manufacturing www.aero-mag.com MATERIALS: TEST & MEASUREMENT he aerospace industry has endured a series of shocks in recent years, including the 2018 Boeing 737-Max crisis followed by the pandemic. While many aspects of the industry have started to recover and show an encouraging trajectory, the aerospace supply chain is facing two major bottlenecks: the shortage of raw materials (such as highresistance alloys or titanium) and the lack of qualified workforce. Together, these challenges are testing the resilience of the complex aerospace supply chain, and there’s no single, simple solution. Aerospace manufacturers see the digitisation of legacy industry processes and the reduction of part scrapping as critical steps to fortify the supply chain, but the implementation of robust, proven, and effective solutions to enable these improvements remains a barrier. The lack of reliable, quantitative information from manual or outdated inspection processes contributes to over-machining and scrapping parts, which then slows down the manufacturing process or even worse, completely halts a production or assembly line. For MRO activities, unnecessary parts scrapping has a serious impact on the direct maintenance cost (DMC), potentially on the turnaround time (TAT), and ultimately on fleet availability. Despite the strict quality control requirements in aerospace, surface inspection is one example of a challenging process where some approximation is often used, due to the lack of quantitative information and the nature of the different materials used in aerospace, like aluminium, titanium, carbon fibre, and transparent acrylic. Current surface inspection methods in aerospace manufacturing and MRO have several weaknesses because many inspections still rely on manual processes like the highly subjective fingernail or thumbnail test to inspect surfaces. The drawbacks to most of the existing methods are: they are qualitative but not quantitative; are not repeatable or traceable; they are time and human capital intensive; can require expensive, complex and static laboratory equipment, and are dependent on the optical properties of the surface to be controlled. Making the digit digital This is where GelSight offers an enormous advantage for the numerous quality control and surface inspection processes throughout the aerospace manufacturing, assembly, and the MRO processes. GelSight’s technology is based on the specific optical properties of an elastomeric sensor (ThermoPlastic Elastomer gel) which precisely conforms to any kind of surface in contact with the gel sensor. The GelSight Mobile system (Fig 1.) uses this tactile intelligence technology to provide rapid, repeatable, nondestructive testing for manufacturing and MRO operations of engines, aerostructures, landing gears, and other critical components. GelSight’s tactile sensing technology is also perfectly suited to measure and analyse Thierry Mantel, vice-president of global distribution and key accounts at digital touch technology specialist, GelSight, discusses how its innovative elastomeric sensing platform brings added benefits to companies involved in aerospace manufacturing and maintenance applications. T TACTILE, DIGITISED INSIGHT INTO SURFACE (Fig 1.) The GelSight Mobile surface scanner system (above) Inspection Thierry Mantel of GelSight (below)
www.aero-mag.com Aerospace Manufacturing November 2023 17 scratches, dents, tool marks, weld inspection, corrosion marks, fastener flushness, shot peening, and more. Additionally, the portability of GelSight Mobile’s enables users to perform these measurements and analyses directly on the shopfloor or under the wing in a maintenance hangar. The quantitative, digital nature of the resulting outputs allows GelSight Mobile to be easily integrated in a smart factory environment and expedite production and assembly cycles in the aerospace industry. The intelligent touch GelSight’s technology uses an intelligent elastomeric sensor that enables instant visual feedback, displaying surface detail on contact using an industrial digital camera sensor and six LEDs mounted in the sensor. From these different illumination channels, six individual images are captured by the digital camera within a fraction of a second. Based on these six images and leveraging a proprietary stereophotography algorithm, the system reconstructs an image of the 3D surface in contact with the sensor within a few seconds. A heightmap of five million data points is then created, allowing the intuitive software interface to provide position, depth, and other 3D surface measurements at a high resolution. This accurate and repeatable measurement and analysis provides crucial information that allows immediate decisions to be made directly on the shopfloor or out in the field. Finally, the automatic generation of a customisable report for traceability and quality assurance closes the process. To illustrate the application of GelSight Mobile on physical configurations, (Fig 2.) and (Fig 3.) respectively present the measurements of the surface roughness of a metallic 3D printed part and a scratch on an engine component. These types of analyses are typically made in only a few seconds with GelSight, compared to the minutes to hours that surface roughness measurements can take with optical methods like confocal microscopes. Authentic applications In most cases, GelSight Mobile has passed strict qualification protocols and is integrated in formal quality control processes both for new manufacturing and MRO operations. The versatility and portability of the GelSight device provides users with a powerful solution that can scan different materials directly on the shopfloor or in a maintenance hangar without the need for different setups. Its accurate and repeatable measurements also ensure fast and well documented decisions. For the engine experts at Germany’s MTU Aero Engines, reliable information on part defects is important to meet the stringent requirements of engine production, identify whether they are minor or major flaws that need to be repaired or replaced, and determine if this will delay the engine assembly. As a result, MTU has replaced its traditional manual impression and lab inspection processes with GelSight Mobile to detect and document even small defects, ultimately accelerating engine assembly. The MTU team now can significantly simplify and speed up inspection procedures, while still arriving at sound results about the quality of engine parts in a reliable and repeatable way. Similarly, cargo airline Kalitta Air’s maintenance team previously relied on a variety of measuring tools including micrometers, calipers, and optical micrometers to perform heavy checks and major overhauls and part repairs. A lot of time was spent measuring and then remeasuring parts, costing thousands of dollars and man-hours per year. By partnering with GelSight, Kalitta’s Maintenance now has a platform to perform detailed, accurate surface inspection processes that can generate significant gains in productivity in a variety of their MRO applications, while also reducing the costs associated with many manual or tool-based inspection techniques. As an example of the cost savings, Kalitta Maintenance was able to reinspect damage on seven individual C-1 blades for a CFM engine, and redisposition them into active inventory, saving the customer US$350,000 in replacement parts using GelSight’s technology. Manual, qualitative measurement and inspection processes are holding the aerospace industry back and it’s time for digitisation throughout the supply chain to help drive the industry forward. GelSight is bringing a disruptive digital solution for the measurement and analysis of surface anomalies such as scratches and dents, or surface finish and roughness. Its ease of use, versatility, and portability makes GelSight a unique and essential tool which can directly be used on the shopfloor. Its accuracy and repeatability also allow fast and documented decision making, which directly leads to productivity gains and major cost savings for aerospace manufacturing and MRO organisations. www.gelsight.com (Fig 2.) Surface roughness measurement carried out on 3D printed part (above) (Fig 3.) A surface scratch detected on an aircraft engine component (below)
18 October 2013 www.aeromag.com ADVANCED MATERIALS: MACHINE TOOLS November 2023 Aerospace Manufacturing www.aero-mag.com Scan here for more Citizen articles istorically, a majority of subcontractor Reginson Engineering’s turnover came from the aerospace sector. So, when Covid struck in early 2020 and aerospace contracts dried up, the AS9100 accredited, Rolls-Royce approved company was deeply affected by the contraction in business. It was mitigated somewhat by the company joining the Ventilator Challenge UK. During April 2020, RollsRoyce asked Reginson Engineering to manufacture 113,000 components in 10 days to support the build of 8,000 ventilators. Towards the end of that month, within 36 hours of an order being placed for a pair of Cincom A20-VIIs sliding-head CNC turning centres to enable the medical contract to be fulfilled, the machines were delivered by Citizen Machinery UK. Both have LFV (low frequency vibration) chip-breaking capability, which not only improved swarf control, raising reliability and reducing the need for operator intervention, but also enhanced the surface finish on components. The medical work was only temporary, however, so the familyrun business owned by Steve Hatch set about finding business elsewhere. What transpired altered the company’s fortunes entirely, as a contract from a jewellery manufacturer combined with strong growth in aerospace conspired to increase turnover so dramatically that by 2023 it was 447% higher than before the pandemic. Even better is to come. The jewellery company is so pleased with the quality of the mainly titanium jewellery pieces already supplied that it has signalled its intention to increase the annual quantity of parts from 100,000 to 1 million per month over the next few years. The machine tools underpinning both the quantity and quality of the jewellery parts produced are yet more Citizen Cincom sliding-head lathes. In October 2020, the lathes were joined on the shopfloor by the subcontractor’s first Citizen fixed-head model, a 64mm bar capacity Miyano ABX-64SYY twin-turret, twin-spindle turn-mill centre. The user describes the machine as being fantastic, as it has allowed cycle times to be slashed compared with using other turning plant on site. Shortly after its arrival, it more than halved the cycle time for producing a component from 4 minutes 30 seconds to 117 seconds complete. The upturn in throughput generated by the jewellery contract required much more sliding-head capacity, so the subcontractor has bought 14 new Cincoms in the last couple of years. They are seven 20mm bar capacity A20-VIIs and the same number of 12mm capacity L12-VIIs. Twelve of them are devoted to jewellery component manufacture and the other two were acquired to boost production of smaller aerospace parts. The latest influx of new lathes plus the recent purchase of two new 5-axis machining centres brings the total number of CNC machines in the Nuneaton factory to nearly 100. Says machine shop manager and family member, Tom Hatch: “We chose twin-spindle sliders for the jewellery work because positioning cutters on gang toolposts for the next operation is much faster than indexing turrets in a fixed-head lathe. It means we can produce components more quickly, not only because there is less idle time, but also because there is more scope for reducing the number of second and subsequent operations.” He added that the machines are easy to set and operate, to the extent that he and one other staff member run 12 Cincom’s located in an adjacent factory unit that has been leased recently for the new project. The finish of the turned surface achieved on the lathes is 0.2µm, which lessens the amount of polishing that has to be done in Nuneaton or by the customer. Similarly, the performance of the Cincoms when producing aerospace parts is excellent due to the extreme rigidity of the machines, despite having to cut materials ranging from tough nickel alloys to titanium and stainless steels. Tolerances down to ±3µm are often turned, saving the time and expense of grinding parts in another operation. Surface finish is also high at up to 0.8µm when required. www.citizenmachinery.co.uk Subcontractor’s turnover more than quadruples in three years, thanks to the company diversifying its portfolio – and the acquisition of some fixed and sliding head lathes from Citizen Machinery UK. H SPREAD YOUR WINGS A selection of largely aerospace components produced by Reginson Engineering (above)
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