1 October 2013 www.aeromag.com www.aero-mag.com CIVIL & DEFENCE/SPACE/SUPPLY CHAIN MAY 2023 MATERIALS A MODEL APPROACH TO ADDITIVE MANUFACTURING Page 20 THE EUROPEAN MAGAZINE FOR A GLOBAL INDUSTRY PARIS AIRSHOW PREVIEW P.12
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Busy with the fizzy! 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 Business Development 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 EVENT PREVIEW 10 AIX: the catalyst for the future – Aircraft Interiors Expo 12 Aim for the stars – Paris Airshow preview 13 Additive manufacturing intelligence – TCT 3Sixty 15 Education all areas at M&E Week – M&E Week AIRCRAFT PROGRAMMES 17 From the shopfloor to the top floor – Military aircraft ADVANCED MATERIALS 20 A model approach to additive manufacturing – Additive manufacturing 22 Advancing the field of NDT – Test & measurement DIGITAL MANUFACTURING 24 A model of digital excellence – Simulation & visualisation SPECIAL REPORT 28 The next level of tool automation – Automation 30 Vacuum technology with ‘wow’ effect – Assembly techniques SUPPLY CHAIN 31 Can recruitment keep up with growth? – Recruitment 32 PRODUCT ROUNDUP FINAL APPROACH 34 A passion for aerospace engineering – Alexandre Marceau-Gozsy, Ricardo’s programme manager Next issue: Events: Paris Airshow edition, Civil aircraft, Technology feature: Engines, Materials: Machine tools, Special report: Automation, Supply chain: Partnerships, Digital manufacturing: Industry 4.0, Final approach When visiting the many industry tradeshows around the world, I’ve come to realise that there can be many different interpretations of the word ‘busy’. Having just returned from the JEC World Paris composites show, this adjective just doesn’t do the event justice. Show organisers, exhibitors and visitors all have their own views regarding what constitutes healthy attendance figures, but at JEC World, there were more queues than at your average call centre. Packed aisles, packed stands, JEC World packed them in with its sheer exhibitor presence and composites joie de vivre. Inside the halls, I was jostled by the throng of visitors rubbernecking to get a better view of the latest innovative products, whilst among the welter of warm welcomes and benevolent backslaps, old acquaintances were renewed and new and mutually beneficial partnerships established. With many aerospace sector exhibitors at the show, there was particular interest in a conference held in the Agora 6 conference hall. Airbus’ head of the Wing of Tomorrow Programme, Sue Partridge told the rapt congregation about its progress. According to Sue, all primary and secondary structure components have been manufactured for three wings, the first wingbox assembly is complete, a test facility is being readied, and folding wing tip ground-based demonstrator production has begun. Proof, if proof were needed, that shows like JEC continue to provide that ‘I saw it here first’ moment. Let us all hope that another fantastic turnout in attendance for JEC’s organisers will allay any industry turbulence - economic or otherwise – that has sometimes preceded many tradeshows in recent years. Based on this evidence and the weight in numbers of happy visitors and exhibitors alike, I won’t be surprised if the aerospace composites materials industry isn’t still growing, thriving, fizzy, and busy for some years to come! Mike Richardson, editor ISSN 2056-3434 www.aero-mag.com Aerospace Manufacturing May 2023 3 COMMENT & CONTENTS Volume 18 Issue 166
4 October 2013 www.aeromag.com Xxxxxxxx 2014 www.aeromag.com NEWS Kyocera SGS Precision Tools (Europe) has announced the appointment of Damian Ward as its new business development manager. With his extensive knowledge and experience, Ward will play a crucial role in driving the company’s growth strategy and strengthening the company’s position in the market. “We are thrilled to welcome Damian to our team,” said Hugh Welch, managing director at Kyocera SGS Precision Tools (Europe). “His diverse background and expertise in the cutting tool industry makes him an excellent fit for this position. We are confident that he will contribute significantly to our business development efforts.” www.kyocera-sgstool.co.uk Nadcap announces AM task group formation May 2023 Aerospace Manufacturing www.aero-mag.com Kyocera SGS makes Ward appointment The Nadcap programme – which provides critical process accreditations of suppliers in the aviation, defence, and space industries – is developing a new Task Group for Additive Manufacturing (AM). The formation of the Task Group, recently approved by the Nadcap Management Council and Performance Review Institute (PRI) Board of Directors, will be the focus of all additive manufacturing activity within the programme, collaborating with the 23 other Task Groups on associated processes. Currently, the Nadcap programme offers accreditation for Laser Powderbed Fusion through the Welding Task Group, but in future this will be conducted via the new AM Task Group. Jay Solomond, executive vice-president and COO at PRI, stated: “Creation of the new AM Task Group is an important step for the aerospace manufacturing industry. Together, we will work towards developing specific audit criteria for AM processes and ensure high quality AM products are manufactured in accordance with the principles of the Nadcap programme. The addition of additive manufacturing accreditation demonstrates how PRI and the Nadcap programme continue to evolve to meet industry needs.” www.p-r-i.org UNASIS International, the bearing and tool manufacturing division of the Carter Manufacturing group of companies has signed an exclusive distribution agreement with Australian company, CGB Precision Products. This agreement underlines the continued expansion of Carter Manufacturing and emphasises their growing global reach covering Europe, America, Asia and now Australasia. CGB supplies high performance bearings and bushes, rod ends, spherical bearings, magnetic brakes, clutches, couplings, load cells, amplifiers and controllers to customers in commercial aerospace and defence industries across the Australasia region. To coincide with the distribution agreement, Carter Manufacturing was able to join CGB at the recent Avalon Air show 2023 in Australia which attracts senior industry and government decision-makers from around the world. Positive feedback for CGB and Carter confirm initial leads generated at the show are already turning into orders. www.carterbearings.co.uk Carter expands into Australasia
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
6 October 2013 www.aeromag.com May 2023 Aerospace Manufacturing www.aero-mag.com EconCore partners on sustainable rudder EconCore has partnered with Airbus, the Technical University of Denmark (DTU) and Fraunhofer on a new green and sustainable type of rudder for an Airbus A320 aircraft based on thermoplastic honeycomb sandwich composites. Airbus, Fraunhofer, DTU and the sandwich core supplier, EconCore will develop a new generation green and sustainable rudder structure based on potentially recyclable thermoplastic materials. It forms part of the project ‘FASTER H2’, funded by the European Union’s Clean Aviation Research Programme under Horizon Europe and led by Airbus. The four partners will collaborate on the work package in FASTER H2, called EcoRudder, which focuses on the development of a new generation rudder structure for a single-aisle commercial aircraft. It is envisaged that the rudder structure will be redesigned and replaced with thermoplastic materials that have the potential to be recycled after the aircraft has been decommissioned. https://econcore.com/en NEWS DESIGN DEVELOPMENT MOULDING TOOLING BEYOND THE MOULD Pentagon delivers a full turnkey solution for plastic injection moulding from one site of UK Manufacture. With over 50 years’ experience you can be confident that your Bespoke Moulding project is in the hands of the experts for both mould tooling and repeat production. www.pentagonplastics.co.uk | websales@pentagonplastics.co.uk Tel: +44 (0) 1403 264 397 | Meet us at this years’ Interplas UK – 26- 28 September at the NEC, Birmingham. Pentagon - Quarter Page.indd 1 06/04/2023 15:59 Velocity Composites has completed the successful manufacture of the first composite production kits from its new advanced manufacturing facility in Alabama, US. The major development at the site supports the signing of a five-year Work Package Agreement in December last year with GKN Aerospace in the US, expected to be worth in excess of US$100 million in revenue over five years. The milestone is the culmination of an intensive period of training, audits, and approvals, during which the site successfully achieved approval of the AS9100, Rev. D quality management system in November last year. This was followed by several prime customer audits through December 2022 and early January 2023 and concluded in full customer audit approval and authority to proceed with First Article manufacture. Jon Bridges, chief executive of Velocity Composites, said: “This is a major milestone for Velocity Composites as we expand into North America. The whole Velocity team, both in the US and UK, have worked incredibly hard to deliver a fully operational site, a welltrained team, and a plan ready to start delivering flying products to our launch customer.” www.velocity-composites.com Velocity hits US facility milestone Solvay and GKN Aerospace have signed an extension to their 2017 collaboration agreement. Under the agreement, both businesses are developing a joint thermoplastic composites (TPC) roadmap to explore new materials and manufacturing processes for aerostructures, while jointly targeting future strategic high-rate programmes. In addition Solvay will remain a GKN Aerospace preferred supplier for TPC materials. “We are excited to continue collaborating with GKN Aerospace,” said Fabrizio Ponte, head of Solvay Thermoplastic Platform. “Going forward, our teams will specifically work on next-generation TPC materials and processes for aerospace applications including commercial aviation and Advanced Air Mobility. Our particular focus on high rate manufacturing solutions for medium and large structures.” www.solvay.com Solvay and GKN renew agreement
© ARNO-ASM-2023-04-UK ARNO (UK) Limited | Unit 9, 10 & 11, Sugnall Business Centre | Sugnall, Eccleshall Staffordshire | ST21 6NF Tel +44 01785 850 072 | Fax +44 01785 850 076 | sales@arno.de | www.arno-tools.co.uk WE LIVE QUALITY TOOLING MAKING SURE EVERYTHING TURNS SMOOTHLY Whether super finishing or heavy roughing aluminium or super alloys, from the lightest and most accurate to the heaviest of cuts – no matter what your turning requirements – ARNO has the right solution to enhance your machining processes. Go to arno.de/turning to find out how you can save time and money with ARNO. ARNO turning tools and inserts for enhanced tool life, highest surface quality, improved productivity and reduced cost per part. TURNS UP PERFORMANCE TO MAXIMUM: HYBRID HOLDERS FOR TURNING This tool holder helps you increase the performance of turning applications to previously unattained heights. The new hybrid holder brings ARNO’s ingenious coolant supply system to the turning zone. Not only does it efficiently cool the flanks but also flushes out and reliably evacuates the chips. The hybrid holder practically does not vibrate at all during machining. That’s why it gives you the best surface quality on every production run.
NEWS Partners extend supply chain partnership thyssenkrupp Aerospace has signed a new seven-year agreement to provide raw material management services to Bombardier. The agreement is an extension of a 15-year-long partnership between the two companies. thyssenkrupp Aerospace manages raw material deliveries to Bombardier’s supply chain by handling material flows from demand forecasting, sourcing, and processing to warehousing and logistics through a dedicated and customised control tower. The use of a control tower ensures a seamless supply of materials to customers and their subcontractors. Digital tools oversee planning, execution, and reporting across the customer sites serviced by thyssenkrupp Aerospace. The control tower closely monitors all operational activities as well as forecasting and order inputs. In this way, it brings transparency to customer supply chains, the ability to act immediately in the case of unforeseen events, and continuous improvement measures. “It is our mission to make the aerospace supply chain more resilient and support our customers in the best possible way,” stated thyssenkrupp Aerospace CEO Patrick Marous. “This is why we are delighted that Bombardier continues to trust us with their raw materials management. The use of a global control tower will enhance visibility for Bombardier and help to make its supply chain more flexible. It is a great example of our strategic approach that goes beyond materials distribution to offering ‘Materials as a Service’.” The new contract with Bombardier will focus on reducing waste, optimising resources, and increasing process efficiency. thyssenkrupp Aerospace is taking measures to increase process efficiency and assist Bombardier in its growth strategy. To that end, the company has recently acquired digitally controlled vertical storage units for its warehouses in Canada – streamlining Bombardier’s supply chain with just-in-time or just-in-sequence materials delivery. www.thyssenkrupp-materials-services.com C M Y CM MY CY CMY K Norco Composites & GRP has announced the development of a 10,000ft2 facility extension to accommodate the increasing demand for its services in the aerospace and defence industries. This significant expansion will bolster the company’s capacity to manage growing workloads and projects while maintaining the highest standards of quality and performance. The extension will be equipped with temperature and humidity control systems, ensuring an optimal environment for composites manufacturing. These systems will guarantee consistent quality in every product Norco produces. Additionally, positive air pressure systems will be employed to maintain a clean and dust-free environment, reducing the risk of contamination, and ensuring that products meet the stringent quality and reliability standards required in aerospace and defence industries. “Norco has always been committed to providing innovative and reliable composite solutions to our clients in the aerospace and defence sectors,” said Steve Ross, programme manager at the facility. “The development of this new extension is an essential step toward fulfilling that commitment while accommodating the growing needs of our customers.” www.norco.co.uk Norco announces facility expansion
ai1679656613338_Minigears 109 x 210 Aerospace Advert INTERIOR 2023.pdf 1 24/03/2023 11:17:02 Innovators and leaders from NASA, UKSpace, BAE Systems, Civil Aviation Authority (CAA) and CGI are among the organisations sharing expertise, strategies, and research at Space-Comm Expo 2023. Organised by Hub Exhibitions in partnership with Farnborough International, Space-Comm Expo, the UK’s largest exhibition dedicated to the commercial future of space, returns to the industry calendar on 7-8 June 2023. The 2023 event agenda is focused on bringing the future of space to reality, covering topics such as the future of the space economy, digital transformation, space exploration missions, space tourism space sovereignty and global space governance, sustainability and debris mitigation, a multi-orbit future, and creating new economies in space. Top-line speakers include: Tim Peake CMG, Dr Alice Bunn, president, UKSpace, Trudy Kortes, director of technology demonstrations, NASA, Kevin Craven, CEO, ADS Group and Elizabeth Seward, head of space strategy & future business, BAE Systems, among others. The place for space to do business, Space-Comm Expo brings together decision-makers across the supply chain to further the commercial space sector with future-altering partnerships and hear from world-renowned experts on the immediate opportunities and challenges facing the industry. Leading industry organisations, including BAE Systems, RollsRoyce, InSpace, Viasat and Jacobs, will be showcasing their latest technology, innovations and insight across the two days. Speaking on the announcement of the programme and the themes of the 2023 event, Kevin Craven, CEO, ADS Group, said: “In Space-Comm Expo’s exciting third year, ADS is proud to continue supporting the truly versatile event that connects, showcases, and celebrates the tenacious UK space sector. “2023 is a pivotal year for the UK space sector with a successful UK launch expected before the end of the year, Space-Comm Expo is a fantastic opportunity for industry to come together and discuss the issues along with the Government strategies which underpin the success of the sector. ADS alongside our industry partners including UKSpace are proud to support the event and represent the interests of organisations of the sector.” Dr Alice Bunn, president, UKSpace, added: “Space-Comm Expo has very quickly become a key date in the space sector’s calendar of events. It provides a fantastic showcase for the sector and an opportunity to share ideas and new developments which critically underpin all our everyday lives.” Taking place at Farnborough International Exhibition & Conference Centre, the expo, now in its third year, is a journey through the supply chain of products, components, solutions, and services that supply the space industry and is dedicated to showcasing the commercial opportunities available within an industry worth £14.8 billion to the UK economy. www.space-comm.co.uk Bringing the future of space to reality
10 October 2013 www.aeromag.com EVENT PREVIEW: AIRCRAFT INTERIORS EXPO May 2023 Aerospace Manufacturing www.aero-mag.com he eagerly-awaited Passenger Experience Conference (PEC) returns on 5 June to the Congress Centre Hamburg. The main plenary session at this year’s conference, titled, ‘A Vision of the Multi-modal Future,’ will focus on how the industry can meet the needs of passengers flying in the second half of this decade and beyond. PEC will then split into two streams that will run in tandem. The first, ‘Delivering for the New Generation of Passenger,’ will explore revitalising air travel and incorporating younger consumers into the mainstream market. The second stream of the programme will explore ‘Succeeding in the Green Revolution’ and how the passenger experience community is innovating and readying itself to reuse, repurpose and recycle the cabin interior. The official PEC Welcome Party, following the conference from 18:00, will also offer invaluable networking opportunities, by bringing together the ‘who’s who’ of the industry under one roof – tickets are also available to nonconference delegates. More than 1,000 products will be on display from leading global airline and cabin interior suppliers. The industry leaders returning to the event include seating specialists Safran, Recaro Aircraft Seating, Jamco Corporation, and Haeco Cabin Solutions; and in-flight entertainment and connectivity (IFEC) providers Panasonic Avionics, Thales Group, Astronics Corporation, Latitude Aero, and Bluebox Aviation Systems. Visitors will find solutions for every aspect of the airline interior environment, including cabin management systems, seating, flooring solutions, galley equipment, IFEC, interior paints and coverings, lighting, lavatory and waste equipment, seating, and more. IFEC will continue to be a clear differentiator for airlines due to the increasing digital dependency of passengers. Against this backdrop, the highly popular IFEC Zone returns, providing attendees with access to experts, products, and services in this space. The zone will feature more than 50 exhibiting companies who will showcase their latest innovations and solutions, with products spanning wireless connectivity hardware and software, bring-your-own-device (BYOD) solutions, seatback systems, 5G, streaming platforms, content services and more. In addition to product innovation spanning seven halls, the event will offer opportunities to hear and learn from the industry’s brightest minds. The free-to-attend CabinSpace Live Seminar programme, running on all three days, will help attendees plan for the future, connecting attendees with leaders and visionaries. Polly Magraw, event director, Aircraft Interiors Expo, said: “Aircraft Interiors Expo 2023 plays a vital role in providing a centralised marketplace for the entire interiors supply chain to come together, not only driving the industry’s progress, but aiding in its recovery. Building on last year’s successful post-pandemic event, we are anticipating this year to be the biggest show yet, with over 7,000 visitors set to attend. “Our comprehensive programme of exclusive and insightful talks is complemented by many opportunities to network with the best of the industry, making AIX the ideal platform for building relationships, identifying new solutions and successfully planning for the future trends.” Aircraft Interiors Expo (AIX) returns to the Hamburg Messe from 6-8 June 2023 in Halls B1–B7. It will follow Passenger Experience Conference (PEC) on 5 June and is co-located with World Travel Catering & Onboard Services Expo (WTCE), which can be found in Halls A1 and A4. Together, the events provide passenger experience professionals with a unique opportunity to identify new products and solutions throughout the cabin. www.aircraftinteriorsexpo.com Aircraft Interiors Expo (AIX) returns to Hamburg, Germany at the perfect time. From 6-8 June 2023, the world’s leading marketplace for the aircraft interiors supply chain is expecting the top 70 airlines to attend alongside the major OEMs, as industry professionals look for innovative solutions that will shape the future of passenger experience. T AIX: THE CATALYST FOR THE FUTURE AIX returns to the Hamburg Messe from 6-8 June (below) Scan here for more AIX articles
Additive impeller part courtesy of Autodesk/Renishaw Canada, hip tracker part courtesy of Renishaw, University of Waterloo and Intellijoint Surgical, and additive globe fixture and part courtesy of Stratasys. ©2023 Blue Photon Technology & Workholding Systems LLC. Hard-to-hold additive parts, and delicate materials are particularly suited to Blue Photon’s technology when secondary machining is required with 3D printing applications. www.BluePhotonGrip.com • 855-777-2040 ® ADHESIVE WORKHOLDING See a live demo at Rapid+tct, booth #3860! MEDICAL AEROSPACE PRODUCTION PROTOTYPING Blue Photon simplifies how parts are loaded to eliminate operations, increasing spindle up-time. NCMT Limited • www.ncmt.co.uk • Tel 020 8398 4277 Optimum electric powertrain in the air Helix develops and manufactures powerful, compact, efficient electric powertrains for aerospace applications. As a full-service supplier we make high performance accessible through Scalable Core Technology in our motor and inverter product ranges. We’re ready to meet your challenge. A story 25 years in the making. Become part of the next chapter. To find out more scan the QR code or visit ehelix.com Visit us at Paris International Air Show, Hall 2B, UK Pavilion, Stand F172
12 October 2013 www.aeromag.com EVENTS: PARIS AIRSHOW PREVIEW May 2023 Aerospace Manufacturing www.aero-mag.com eld at Le Bourget from 19-25 June, the Paris Airshow is the world’s largest aerospace industry event, drawing decision-makers and influencers from around the world for a showcase of aviation, aerospace, and defence innovation. This year’s show - the first since the pandemic - is expected to surpass the 2019 edition, which hosted nearly 140,000 trade visitors, 2,500 exhibiting companies from 49 countries, and 300-plus official delegations. A much-anticipated highlight of the 54th Paris Airshow this summer will be the return of Apollo 16 Lunar Module Pilot, Brigadier General Charlie Duke, USAF (Ret), as a goodwill ambassador of the USA Partnership Pavilion and the Astronaut Al Worden Endeavour Scholarship. Duke will be joined by former French Astronaut-Cosmonaut Général de Brigade Jean-Loup Chretien, Armée de l’Air (Ret); former NASA astronaut, Col. Michael Bloomfield, USAF (Ret); and Endeavour programme founder, USA Partnership Pavilion organiser Tom Kallman, to announce the host country’s first scholarship recipients of a week-long, hands-on astronaut training experience at Space Camp in Huntsville, Alabama later this summer. A lifetime commitment Kallman launched the Endeavour programme during the 53rd edition of the show in 2019 with Duke and fellow astronauts Walt Cunningham (Apollo 7) and scholarship namesake Al Worden (Apollo 15) in recognition of Worden’s lifetime commitment to promoting science, technology, engineering, and math (STEM) education. Since then, with the support of global partners in government, industry, and academia, the programme has navigated the pandemic to award scholarships to 32 students and eight educators representing the United Arab Emirates, Chile, Singapore, and the UK. The French mission crew will be announced at the show on 22nd June during the Endeavour Scholarship Award Ceremony, and will join fellow scholarship recipients from Australia, Bahrain, and the US in July in Washington, DC, then onward to Huntsville for their Space Camp experience. “We’re honoured to welcome Charlie Duke back to the USA Partnership Pavilion at the Paris Airshow to continue the mission we launched in 2019 to inspire future generations of explorers, engineers, and pioneers,” says Kallman. “We also remember Walt and Al, who have since passed away; poignant reminders of how privileged we are to learn first-hand from Apollo astronauts about the importance of STEM education in improving life on Earth and helping humanity reach for the stars.” Adds Duke: “I am proud to return to Paris to help inspire the next generation of industry leaders and to recognise the achievements of our Endeavour Scholars. In my experience, no other event presents such an opportunity to demonstrate the importance of international collaboration – another one of our Endeavour programme’s tenets.” For the 28th consecutive year, the USA Partnership Pavilion will be the largest international pavilion at the show, hosting more than 300 exhibitors across some 6,000m2 in hall 3. In addition to organising and supporting the exhibition space during the trade days, Kallman Worldwide will also host ‘Spaceport USA’ a three-day STEMfocused pavilion-wide experience for students and the general public starting Friday, 23rd June and continuing through the weekend. www.kallman.com Apollo 16 Lunar Module pilot, Charlie Duke is set to return to the Paris Airshow 2023 as Endeavour Scholarship Ambassador. H AIM FOR THE Apollo 16 Lunar Module Pilot, Brigadier General Charlie Duke (right) Scan here for more Kallman articles Stars Kallman will host its STEM-focused experience for students and the general public at the event (below)
www.aero-mag.com Aerospace Manufacturing May 2023 13 EVENT PREVIEW: TCT 3SIXTY irmly established as the UK’s definitive and most influential 3D printing and additive manufacturing event, TCT 3Sixty will bring together market leading technology suppliers, service companies and a huge free additive manufacturing and 3D printing conference, all at the home of the UK additive manufacturing and 3D printing industry. TCT 3Sixty creates an exciting, engaging and inspiring experience for all visitors. Taking place on 7-8 June 2023 at NEC Birmingham, TCT 3Sixty is a must-attend event for aerospace and defence professionals looking to evaluate, adopt or optimise additive manufacturing technologies for their organisation. Discover the very latest developments from over 200 exhibitors including: Lightweighting - get to grips with the latest software developments in generative and topological design to optimise fuel efficiencies across an aircraft’s lifetime; Learn how smart design for additive manufacturing can be used for part consolidation to create more efficient assemblies and reduce part sourcing; See real world examples of critical and non-critical aerospace components - from cabin interiors to fuel nozzles; Low hanging fruit - it’s not all about end-use parts, find out how using 3D printing for manufacturing aids and tooling on your production line can significantly reduce lead times and costs; Supply chain - find out how additive manufacturing can be deployed as a tool for resiliency with localised, on-demand manufacture; Spare parts - time is money, learn how 3D printing can be used to reduce part inventory and create more sustainable solutions for sourcing spare parts, as and when needed, to keep aircraft flying. The aerospace and defence sector views additive manufacturing as a critical technology. This June, TCT 3Sixty will show you how to get the best from it. F ADDITIVE MANUFACTURING INTELLIGENCE TCT 3Sixty’s TCT Awards celebrates the best innovations and applications of AM technology (above) The TCT 3Sixty conference will deliver compelling 3D printing and AM insights, across four stages. Almost 100 speakers with over 1,000 years of 3D printing and additive manufacturing experience are ready to inspire you. The TCT 3Sixty conference is a must-attend for anyone looking to evaluate, adopt or optimise additive manufacturing technologies within their business. All about aerospace This year TCT 3Sixty have sessions specifically focused on aerospace. Hear from expert speakers as they discuss the latest developments in AM in the aerospace and defence industry: Developing Parametric Sets to Deliver Flying Space Metal Additive
EVENT PREVIEW: TCT 3SIXTY 7 8 JUNE 2023 NEC, Birmingham, UK SCAN ME Evaluate. Adopt. Optimise. With more than 100 speakers and 200 exhibitors, discover your additive strategy at TCT 3Sixty. Sign up Now! www.tct3sixty.com 12 shows, 1 venue 3D PRINTING & ADDITIVE MANUFACTURING INTELLIGENCE Manufacturing Parts by Sebastien Eyrignoux, additive manufacturing project manager at LISI Aerospace; Additive Manufacturing in the Aerospace Industry by Vijay Jagdale, associate director and discipline lead for additive methods, Applied Research and Technology at Collins Aerospace; The Industrialisation of Low Earth Orbit by Mike Curtis-Rouse, head of Beyond Earth, Satellite Applications Catapult. TCT 3Sixty sees this as the best way to drive the UK market forward, remove barriers to learning, enable access to the knowledge base we have here and overseas, and supercharge adoption and increased usage of these amazing technologies across all sectors of industry in the UK. TCT 3Sixty has one goal: to make you better equipped to realise the benefits of 3D printing and AM technology. Whether you are a design, engineering or manufacturing professional who is ready to invest for the first time, looking to upgrade, need to optimise your existing machines or you just want to absorb every bit of new information, TCT 3Sixty has everything you need in one place. And if that’s not enough, visitors will have access to an exclusive Event Hub and App to help build a unique diary of conference sessions and meetings, discover AI recommended products and suppliers, and connect with peers. This is an ideal opportunity to join companies such as Rolls-Royce, BAE Systems, AWE, GKN, Moog and the MoD who have already secured their registration for June. At the end of day one, TCT 3Sixty will hold its awards programme, TCT Awards in celebration of the very best innovations and applications of 3D printing and additive manufacturing technology globally. The aerospace and defence industries are renowned for leading the way in innovation. From developing new and ground-breaking materials, to advanced electronics and automation, technologies incubated by these industries, such as structural composites quickly became popular in many commercial applications. It is therefore unsurprising that these industries have been key adopters of 3D printing and additive manufacturing, and TCT 3Sixty will showcase pioneering applications that have won the TCT Aerospace & Defence Application Award. The black-tie event hosted by David Croft, lead commentator for Sky’s Formula One coverage, will also celebrate the TCT Women in 3D Printing Innovator Award which recognises the incredible work women are undertaking in the additive space, the TCT Hall of Fame, which heralds individuals who have dedicated a lifetime of work to the additive manufacturing Industry, and in its inaugural year, the Sanjay Mortimer Foundation Rising Star Award which will recognise an up-and-coming neurodivergent young person who has the potential to contribute greatly towards the engineering industry. www.tct3sixty.com Scan here for more TCT 3Sixty articles TCT 3Sixty’s goal is to make you better equipped to realise the benefits of 3D printing (above)
www.aero-mag.com Aerospace Manufacturing May 2023 15 EVENT PREVIEW: M&E WEEK ducation has always been a major part of the Smart Factory experience, and this has only expanded through its integration into M&E Week. Two paid conferences, The Manufacturing Digitalisation Summit and The SME Growth Summit, are taking place but a major additional attraction of Manufacturing & Engineering Week 2023 is the free-to-attend conference programme across two Keynote Theatres and six Solutions Theatres. The first Keynote Theatre hosts a range of opinion leaders talking, or chairing panel sessions, on a wide range of relevant topics. The full programme is nearly finalised. One keynote session, on 7th June, that immediately catches the eye is from Katherine Bennett CBE, CEO of the High-Value Manufacturing Catapult (HVMC). Speaking on the topic of Innovation as the Key to Business Transformation & Growth the session discusses the importance of innovation to change manufacturing businesses for the better and includes examples of how Bennett has seen this working The second annual Manufacturing & Engineering Week draws ever closer. A multitude of events will take place as part of the event including Smart Factory Expo, Design & Engineering Expo, the Drives & Controls zone and Maintec on the 7-8 of June at Birmingham’s NEC. E EDUCATION ALL AREAS AT M&E Week’s Solutions Theatres will include topics such as automation & robotics (below) with companies that the HVMC are supporting. Also, of great interest is a case study session on 8th June entitled, The unstoppable rise of Digital Twins. This session, featuring Ben Wilkinson, head of digital technology, and Nipuni Karunaratne, model factory manager, both of Rolls-Royce Civil Aerospace, covers the company’s introduction of a radical new business model in the 90s that catalysed the development of early analytics. This model grew over time into a connected ecosystem of digital twins and this session will explore that journey and examine the cultural, behavioural and technological factors that enabled it. The second keynote theatre is dedicated to the Maintec event. Maintec is the longest standing exhibition for the predictive maintenance, reliability and asset management industry and throughout its long history, the event has continued to focus on uptime and the tools, innovation, technology and people that support it. RS is sponsoring the Maintec theatre and will be presenting findings from a recent survey of more than 1,000 maintenance professionals as well as the founder of RS Industria, Richard Jeffers, presenting a thought-provoking session entitled: Predictive Maintenance as a way of life – not a technology. M&E Week
EVENT PREVIEW: M&E WEEK In addition to hosting presentations on perennially important topics such as eliminating downtime, the theatre will also see several case studies presented as well as looking to the future of maintenance with papers and panel discussions on the role of artificial intelligence and machine learning. One conference session to mention (which is taking place in the Maintec keynote theatre but would be worth attending wherever it was staged) is from Engineers Without Borders UK. Their keynote session on the afternoon of Wednesday 7th June will see the launch of a Global Responsibility Competency Compass. The Competency Compass is a must for those who are struggling to respond effectively to the complexity, uncertainty and challenges of the age. The action-oriented tool, developed through extensive consultation and testing, articulates the essential skills, knowledge and mindsets that engineers increasingly need to deliver the most positive impact on the four principles of global responsibility: responsible, purposeful, inclusive and regenerative. For those in manufacturing businesses who want to achieve something regarding their sustainability challenges then this session is a ‘must see’. It’s not to be forgotten that alongside the two keynote theatres there are in addition six Solutions Theatres. Topics include key areas of interest: Automation & Robotics, Digital Transformation, IIoT & Connectivity, Industrial Data & AI, Innovation and Design Engineering. Additional free educational sessions are being hosted by the Institute for Manufacturing in the IfM Theatre. Its masterclasses are designed to challenge and extend the attendees’ thinking in relation to some of the most pressing challenges and opportunities they face. IfM uses research and frameworks developed at the University of Cambridge so those attending the masterclasses can gain practical insights and recommendations. IfM Industrial Practitioners have extensive expertise in supporting organisations across many sectors, and so are ideally placed to answer any questions and unpick problems. The final timetable for this year’s masterclasses will be released shortly but previous strategic masterclass topics have included: Strategic Roadmapping, Technology and innovation management, Sustainability – Scope 3 emissions, Sustainability - Reducing energy waste and Digital strategy. IfM Masterclasses require advance booking, and this can be done when registering for your ticket to visit Smart Factory Expo. The week beginning 5th June 2023 is Manufacturing & Engineering Week with the centrepiece exhibitions Design & Engineering Expo, Smart Factory Expo, Maintec and the Drives & Controls zone taking place at Birmingham’s NEC on 7th and 8th June. Other exhibitions are also taking place at the NEC during the week and these include Automechanika run by Messe Frankfurt; Med-Tech Innovation Expo and TCT 3Sixty from Rapid News Group and Subcon from the Mark Allen Group. www.mandeweek.co.uk Scan here for more M&E Week articles Free educational sessions are being hosted by the Institute for Manufacturing (below) ROBUSTNESS AND TECHNOLOGY TO ITS FULL EXTENT Discover the lastest generation of bridge type and bed type milling machines with 4-axis and 5-axis. Boost the productivity and flexibility of your large parts by including the turning capability or the automatic head & pallet changer options. https://www.nicolascorrea.com/en NicolasCorrea_am_0523.qxp_Layout 1 02/05/2023 12:27 Page 1
www.aero-mag.com Aerospace Manufacturing May 2023 17 AIRCRAFT PROGRAMMES: MILITARY AIRCRAFT hile Industry 4.0 has been a mainstay of most manufacturing processes for some time, ‘Aerospace & Defence 4.0’ has matured a little more slowly. A&D 4.0 is now seriously up and running - and that means the spotlight is on the vital role Manufacturing Execution Systems (MES) must play to get critical data off the shopfloor and into the systems that will unlock better production execution, quality control, and Overall Equipment Effectiveness (OEE). It also makes the world of Defence Contract Management that much simpler with fully integrated and automated workflows and it helps solve an array of human capital issues. In 2020, IFS conducted research into the A&D 4.0 maturity curve with surprising results. The polling results from a webinar attended by A&D manufacturers found that only 12% of nearly 150 attendees had not made Industry 4.0 an enterprise-wide priority, while the majority of the remaining manufacturing companies (68%) were still researching how these Matt Medley, IFS’s global industry director of A&D, examines the key role of Manufacturing Execution Systems and how they are helping drive ‘Aerospace & Defence 4.0’. W FROM THE SHOPFLOOR TO THE TOP An MES can unlock the benefits of A&D 4.0 and vertical integration of manufacturing (above) Floor
technological advances could help achieve their digital transformation goals. While the interest in 4.0 technologies was clear to see, the A&D market was still at the beginning of the adoption journey. Bridging the chasm from interest to adoption was going to rely on positive results from early adopters prospering from deploying the latest solutions. Things have now taken off. The widespread emergence of Industry 4.0 technologies is here and their implementation on flexible enterprise software platforms is helping unlock previously inaccessible financial, operational, and security benefits for A&D manufacturers. Enlisting powerful MES is now pre-requisite to positively unlocking these benefits and has a hugely positive impact on production rate and execution, quality control, and OEE. MES transforms inventory, production, and quality control activities to deliver efficient and compliant work execution by digitally tracking and documenting the endto-end manufacturing process. These systems digitally capture each step of the transformation of raw materials into finished goods for documenting compliance, data-driven continuous improvement, and supply chain transparency in real-time. 18 October 2013 www.aeromag.com May 2023 Aerospace Manufacturing www.aero-mag.com AIRCRAFT PROGRAMMES: MILITARY AIRCRAFT A&D MES support must have the ability to add additional 0.9 decimal places to manufacturing quality control Scan here for more IFS articles MES is a key part of the vertical integration of manufacturing by ensuring data is accessible from the shopfloor to the top floor, continuously fed to real-time dashboards and enabling control at every level of the manufacturing organisation. From the supervisor on the shopfloor, to the director of operations, to the quality systems, and even having that information rolled up to the C-Suite, everyone in the chain has real-time information for actionable intelligence. Exacting requirements The devil is in the details for A&D manufacturers, which MES data must be able to provide. Unlike traditional discrete manufacturing of parts and assemblies, A&D equipment is held to a higher standard of accuracy and safety. Engineering tolerances for aircraft can be down to the thousandths of an inch. A&D MES support must have the ability to add additional 0.9 decimal places to manufacturing quality control. It’s this level of quality and precision that MES in A&D manufacturing are held to, and these incredibly stringent tolerances are built in for safety and mission effectiveness. Failure of either of these elements has huge consequences in A&D wherever the equipment is operating, potentially causing catastrophic equipment failure to compromise mission success and even put the warfighter’s life at risk. Having MES accessible as part of a core manufacturing solution offers significant benefits. Separate MES is not conducive to providing the level of vertical reporting required in a modern manufacturing environment, nor is MES always able to provide the additional level of granularity and specificity necessary to operate in the A&D manufacturing sector. However, working with complex point solutions with heavily customised integrations to solve these issues and move information across an A&D manufacturing organisation is time-consuming to manage and risks soloing out data that would otherwise be critical to the overall production execution, quality control, and KPIs like OEE. An all-in-one MES It’s the MES that tracks the daily operation level of your shopfloor. Software with built-in MES functionality provides the essential digital backbone between the proliferation of smart devices and machines and core manufacturing planning software, seamlessly integrating this technology with the higher-level software used to plan production. In this way, open interoperable MES solutions enable full traceability of parts, components, and projects - from design right through to production and engineering. As a pre-requisite, MES functionality should enable CAD integration, robust, An MES tracks the daily operation level of your shopfloor (above) Matt Medley, IFS’s global industry director of A&D (below) Getting MES right is a critical component of A&D 4.0 (below right)
www.aero-mag.com Aerospace Manufacturing May 2023 19 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 real-time data collection, and more sophisticated integrations through IoT and RESTful APIs as just a few examples. It also needs to support dispatching and shopfloor operation, improved production management and tracking, and quality management processes. Then there’s the need to enable machine monitoring and performance and KPI reporting. Critically, instead of having to get a different MES and then tie it all together with other manufacturing solutions, MES should be part of one software package that’s not just integrated, but all one fully-connected piece ‘out-ofthe-box’. The next level of automation Once A&D manufacturers have established this connected base point in a single system, they can then exploit new and emerging automation functionalities that unlock further intelligent insights and accelerate automation efforts within their business practices. From an MES perspective, this can include streamlining to improve product quality control and performance and the use of artificial intelligence (AI) and historical data-driven work schedules and job completion time to improve accuracy for technical productivity. Also, by combining IoT data with AI/ machine learning, manufacturers can improve performance based on an array of historical observations and transactions. Within Defence Contract Management this streamlined approach between different operational areas of the business means A&D manufacturers can get automated reports done faster and more accurately - to ultimately receive faster payment. With MES, we aren’t talking about advanced robotics that are expensive, timely to implement, and require extensive change management within the A&D manufacturing organisation. It’s changes like improved MES that optimise processes that have started to take hold a lot faster. A&D manufacturing, like many other industries, is experiencing a skilled labour shortage. According to Future Aviation Aerospace Workforce, the manufacturing industry needs 3.5 million workers just for A&D by 2026. This is where a connected MES/ERP solution brings human capital benefits. By improving processes with better feedback on MES data, instead of having to cut staff, A&D manufacturers can upskill employees for higher level work while the factory is automated. It’s a win-win from a change management perspective, as it’s easier to sell a process improvement rather than introducing an army of robots onto the factory floor. MES - a key stepping-stone Getting MES right is a critical component of A&D 4.0 - particularly given the unique requirements of the A&D industry. MES has been around for some time, but its capabilities have had to grow and evolve. It has had to keep up with new and emerging trends just like the rest of the A&D manufacturing software stack does, and that includes connection to lower-level equipment and the ability to export data for analysis and decision making. For these very reasons, for MES to drive improved production execution, quality control, and OKPI management, it cannot sit in isolation from other manufacturing systems. MES must be an embedded part of a wider solution to enable manufacturers to unlock the benefits of A&D 4.0 and vertical integration of manufacturing. www.ifs.com
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