Engineering precisely what you value — Ecospeed www.starrag.com Just in time Customised aircraft solutions due to parallel kinematic machining head Sprint Z3 reduction of part machining time 75%
Holding out for a hero 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 8 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 2024 Printed by: Pureprint Group 4 NEWS AIRCRAFT PROGRAMMES 8 The circle of life – Military aircraft SPECIAL REPORT 11 Mission possible – MRO 12 Fresh thinking – Careers 14 Parts cleaning excellence – Component cleaning MACHINING TECHNIQUES 16 Between the real and virtual worlds – Additive manufacturing ADVANCED MATERIALS 18 Advancing aerospace excellence – Coatings DIGITAL MANUFACTURING 20 Embracing digital technologies – Industry 4.0 EVENT PREVIEW 22 Farnborough Airshow roundup FINAL APPROACH 30 Navigating the skies – John Stretton, the Manufacturing Technology Centre (MTC) director of aerospace, defence and security Next issue: Events: Farnborough Airshow, Civil aircraft, Technology feature: Engines, Materials: Composites, Machining techniques: Machine tools, Special report: Automation, Digital manufacturing: Industry 4.0, Final approach Hello and welcome to our May/June issue of Aerospace Manufacturing magazine. In this issue we preview the Farnborough International Airshow 2024 (see page 22). Taking place 22 26 July, FIA 2024 will host leading innovators from the aerospace sector and beyond. It’s become a global stage on which to showcase the latest innovations and embark on ground-breaking collaboration and partnerships. Flick through the pages of this edition and you can read all about Milexia Italy and how it is addressing lifecycle challenges for the longevity of military aircra . Elsewhere, AI so ware specialists, Plataine discusses workforce challenges with digital transformation. But back to FIA 2024 and something that caught my eye. Developed with young adults, parents and guardians and lovers of all things aerospace in mind, its ‘Pioneers of Tomorrow’ programme is set to o er a meaningful understanding of what careers across the aerospace industry promise: the skills required and the value that studying STEM subjects delivers. Perhaps our industry needs the kinds of ‘pioneers’ that young aspiring engineers can look up to. For example, is there anyone o the telly that can project a positive image of engineering to potential students? Film heroes and celebrities can have a powerful in uence on youngsters considering a career in engineering. Do we need a list of inspirational gures prompting youngsters’ awareness in science and engineering? Maybe the engineering profession will always be seen as a ‘dirty’ career. Maybe it represents too much of a technical challenge for young minds to comprehend. Let’s hope programmes like the FIA’s ‘Pioneers of Tomorrow’ succeed in raising young people’s aspirations, bridge the gap between education and work and give them access to real experience of the world of work. Next up is our July Farnborough Airshow edition. Until then, stay safe and keep the manufacturing ag ying! Mike Richardson, editor ISSN 2056 3434 www.aero-mag.com Aerospace Manufacturing May/June 2024 3 COMMENT & CONTENTS Volume 19 Issue 175
4 October 2013 www.aeromag.com Xxxxxxxx 2014 www.aeromag.com NEWS The next generation of leaders are invited to experience the world of aerospace, engineering and STEM at Farnborough International Airshow’s (FIA) Pioneers of Tomorrow, a dedicated day to inspire, engage and recruit the industry’s future workforce. Organised in collaboration between Farnborough International and ADS, and as part of the FIA, the event will take place on Friday 26 July 2024 and will provide industry exhibitors an opportunity to engage with and inspire future aerospace recruits. With a global skills shortage across the industry, the UK aerospace industry is focused on positioning itself as an attractive and viable career opportunity for the future workforce. Aimed at school children aged 11+ to school leavers, graduates and career movers, Pioneers of Tomorrow will introduce the next generation of leaders, innovators, and pioneers to employers, providing valuable insight into the wealth of career opportunities available throughout the global industries the airshow represents. Free for under 21s, students and apprentices, attendees will be able to immerse themselves in a vast range of on-site STEM focused activities, as well as watch the full ying display, explore the comprehensive static aircra display and speak to leading industry organisations directly. Developed with young adults, parents and guardians, and lovers of all things aerospace in mind, Pioneers of Tomorrow will oer a meaningful understanding of what careers across the aerospace industry promise; the skills required, and the value that studying STEM subjects delivers. A dedicated Careers Hub will feature within the airshow exhibition, providing a platform for students, graduates and young professionals to access one-on-one specialist advice, topical seminars, and a live jobs board. www.farnboroughinternational.org Explore the world of aerospace at FIA Thompson Aero Seating is putting the spotlight on an o en-overlooked aspect of seating design: the colour, materials and nish (CMF). Inspired by the landscape of Northern Ireland, Project Echo is the latest aircra interiors design-development from Thompson. It is a new project from the CMF team, looking at the company’s surroundings and current industry key trends, and now showcased in the latest Vantage seating range. Belinda Mason, CMF designer at Thompson Aero Seating, said: “Our aim has been to create a narrative for Thompson that is a reection of our culture. We have interpreted colours and textures into visuals, using nature and the chemistry of its colours as our inuence. The result is a feeling of quiet luxury.” www.thompsonaero.com/project-echo Thompson unveils new seating aesthetic May/June 2024 Aerospace Manufacturing www.aero-mag.com Subcon 2024, scheduled for June 5 6 at the NEC, Birmingham is the premier event for manufacturing buyers across all sectors. As a cornerstone event for the industry, Subcon provides an opportunity to source your next manufacturing solutions from a variety of world-class exhibitors. With over 150 subcontractors and outsourced engineering services, Subcon is packed with possibilities for everyone. This year’s event promises a refreshed and innovative format, with new developments introduced to adapt and enhance the experience for both visitors and exhibitors. Attendees can look forward to a dynamic programme featuring interactive CPD-accredited workshops, cutting-edge product demonstrations, and insightful keynote presentations. Additionally, you can engage in meaningful discussions through roundtable sessions that are designed to foster collaboration and idea-sharing. Meet with over 150 leading UK and international suppliers under one roof, showcasing the latest innovations and solutions available from sectors such as CNC machining, metal fabrication, electronics, component parts, and more, all dedicated to advancing the capabilities of your supply chain. www.subconshow.co.uk Discover your next partner at Subcon
6 October 2013 www.aeromag.com May/June 2024 Aerospace Manufacturing www.aero-mag.com NEWS JEC and Targi w Krakowie (Trade Fairs in Krakow) have announced the launch of a new event, JEC Forum Central Europe dedicated to bringing together suppliers and buyers from the region. The inaugural event will take place in Krakow, Poland, on September 17 18, 2025. Following the success of established JEC Forum events in Italy and the DACH region, JEC Forum Central Europe aims to provide a focused platform for business interactions within the rapidly growing composites market of Poland, Czech Republic, and surrounding countries. JEC Forum Central Europe is envisioned as a biennial event that will alternate with KOMPOZYT EXPO, starting 2025. Every two years it will be rotating to dierent cities in the region. This alternation will ensure a continuous and strengthened presence in the region, providing regular opportunities for meetings and exchanges for the composites industry in Central Europe. “We are thrilled to launch the JEC Forum Central Europe and contribute to the dynamic growth of the composites industry in this region,” stated JEC’s regional events director, Anne-Carole Barbarin (pictured second le). “This event will provide a unique platform for targeted business interactions and valuable market insights, fostering collaboration and innovation.” www.jeccomposites.com The National Composites Centre (NCC) has released a case study detailing their successful delivery of the design and manufacture of vital one-off flying parts to facilitate UK capability towards accelerating new technologies to decarbonise the aviation industry. The wing demonstrators are in support of Airbus’ innovative eXtra Performance Wing project to optimise wing aerodynamics and aircra performance through hinged wingtips inspired by the biomimicry of seabirds. Enhancing aerodynamics requires the eXtra performance wing to be longer, thinner, and lighter than the standard wing – causing it to be more exible, and more susceptible to turbulence. The NCC’s support was sought to design and manufacture the key structural elements for a 6m section of the wing to relevant aerospace standards. Airbus’ eXtra Performance Wing will use a Cessna Citation VII to ight test new systems including hinged wingtips and an adaptable trailing edge which can be used to modify the wing shape mimicking a bird’s ability to adapt to ight conditions. This could reduce the maximum loads on the wing, enabling the use of higher aspect ratios and unlocking their potential fuel burn bene¤ts. www.nccuk.com NCC enables wing aerodynamic innovations JEC announces new Central Europe event AML wins business excellence award Advanced Manufacturing (She eld) Ltd (AML) is celebrating a er the announcement that its 100-strong team have been awarded the King’s Award for Enterprise Innovation. This award acknowledges how AML’s development and application of novel technologies and lean processes, including forging, automation and robot loading, unlocked a two-fold improvement in productivity that enabled an aerospace prime to expand into the lucrative private aircra market. The Award highlights an innovation in the precision manufacture of complex aerofoil geometries for jet engines. www.amlshe eld.co.uk GKN Aerospace signs Safran agreement GKN Aerospace has strengthened its long-term partnership with Safran, a er signing a decade-long agreement to expand its support for the LEAP engines. The contract covers new shas and spare part production for the Leap 1A variant for the Airbus A320neo aircra, with the expectation to produce similar components for the LEAP 1B for the Boeing 737 MAX aircra in the future. Through this contract, GKN will support Safran with its future demand and will start up new Sha production at GKN Aerospace’s global centre of excellence in Kongsberg, Norway. The ¤rst shas are expected to be delivered from GKN Norway to Paris in the second half of 2024. Alexander Andersson, senior vice-president of GKN Aerospace’s Engines business, said: “This is a signi¤cant agreement and another important milestone in our partnership with Safran. The LEAP is at the forefront of the industry and we are proud to increase our presence on the engine today, while continuing to explore new technology development for the next-generation RISE engine.” www.gknaerospace.com
Arrowsmith secures largest ever order book Arrowsmith Engineering (Coventry) has secured a string of new multi-million pound contracts – just a few days a er it was named as a King’s Award for Enterprise winner for International Trade. The company has sealed long-term agreements with ITP Spain, Incora and Rolls-Royce in the UK and Germany, delivering the largest order book in its 57-year history. It marks what has been a strong export period for the business, with overseas sales rocketing by nearly 400% and accounting for 35% of the rm’s annual £8.3 million turnover. Jason Aldridge, managing director of Arrowsmith Engineering, commented: “It has been some week; from securing the International Trade title in the King’s Award for Enterprise on Monday to announcing our largest orderbook, underpinned by these landmark long-term agreements with some of the biggest names in aerospace. “The King’s Award is fantastic news for our business and is testimony to how our sta have gone above and beyond to help us overcome the troubles of the pandemic and emerge even stronger.” Plans are now in place to take annual sales past £25m over the next two years and this should result in the creation of a further 15 positions, with the focus on getting more women into engineering. www.asg-group.co/arrowsmith King Charles III becomes patron of the RAeS The Royal Aeronautical Society has announced that His Majesty King Charles III has agreed to become its patron. His Majesty’s patronage underscores the Society’s commitment to the advancement of aeronautical art, science, and engineering around the world. The Society is proud of its longstanding association with the Royal Family over the last century. In 1918 King George V awarded the ‘Royal’ prefix to the Aeronautical Society of Great Britain, which became the Royal Aeronautical Society. In 1966 HRH the Duke of Edinburgh became the Society’s Honorary President for the Society’s Centenary Year, followed in 2016 by the then Prince of Wales in the same role for the Society’s 150th anniversary. www.aerosociety.com Coatings engineered for the environment and for performance Composite coatings Talk to our team to find out more today +44 (0)121 702 2485 • sales@indestructible.co.uk • indestructible.co.uk Diffusion coatings Sacrificial base coats and seal coats
8 October 2013 www.aeromag.com AIRCRAFT PROGRAMMES: MILITARY AIRCRAFT May/J une 2024 Aerospace Manufacturing www.aero-mag.com he longevity of military aircra , if handled correctly can span several decades. This is important considering the average Boeing aircra can cost anywhere from $89 million to more than $442 million, depending on the model. Because of the considerable expense involved in buying new aircra , the military aerospace industry takes the issue of extending an aircra ’s lifespan very seriously, and e ective supply chain management solutions are paramount. Distributing high-reliability components for military aircra throughout their entire lifecycle presents multi-layered supply chain challenges. Adding to this complexity is obsolescence management as internal components for these aircra systems, including semiconductors, and mechanical parts, have much shorter lifecycles, in some cases less than ve years. The prolonged operational lifecycles of military aircra in parallel with rapid technological advancements create a dynamic landscape where components risk obsolescence before the end of an aircra ’s service life. This means managing products with long lifecycles, alongside balancing the engineering costs for eliminating internal essential components with shorter lifecycles as absolute. Supply chain disruptions, tightened budget controls, legacy system integration, and regulatory obligations further intensify the urgency for eective obsolescence management systems. To address this ‘two-speed’ challenge military aerospace organisations must implement a complete lifecycle management framework that quali es, all component aspects occurring during the complete lifecycle of the system. One that on every level strengthens the integration of technologies, processes, and methodologies to ensure the agility, upgradeability, and sustainability of military and aerospace systems. Here are some of the important considerations for developing a complete management lifecycle framework: Processes • lifecycle forecasting – implement proactive tools and methodologies to predict and monitor potential obsolescence issues. • In-depth quali cation process - successful quali cation, of all aspects Giuseppe Bergamaschi, sales director of Milexia Italy looks at how best to address lifecycle challenges for the longevity of military aircra . T THE CIRCLE OF Distributing components throughout an aircraft’s entire lifecycle presents many challenges (above)
10 October 2013 www.aeromag.com AIRCRAFT PROGRAMMES: MILITARY AIRCRAFT May/June 2024 Aerospace Manufacturing www.aero-mag.com occurring during the complete lifecycle of the system must be implemented. For the integration of the components into the manufacturing process, component deviations need to be considered as well as component tolerances within the quali cation process. Additionally, the reliability of components and sub-systems considering the harsh environmental and operational situation within military air vehicles has to be taken into account. • Circular economy strategies – develop refurb, repair, and recycle strategies to extend life and make the best use of components in the lifecycle. • Robust supplier veri cation - to eliminate the risk of counterfeit technologies. Counterfeit components are oen dicult to identify by visual inspection alone. As such, businesses must take proactive measures to detect these fake parts from the supply chain, by having strong relationships with veri ed suppliers. • Aircra manufacturing diligence – abide by the aircra manufacturer’s recommended maintenance schedule and schedule repairs, routine servicing, and inspections accordingly. Ensure all maintenance work is carried out by a highly skilled maintenance crew that can provide expertise about an aircra’s unique and ultimate operating conditions and state of maintenance. • Enforce a service life assessment programme - consider a formalised service life assessment, to optimise the lifecycle potential of military aircra. Real-time monitoring will identify issues as they arise rather than using an interval-based maintenance model. Aircra should be systematically rotated to dierent tasks, in dierent phases of their lifecycle to test for longevity, agility, and capacity to upgrade or transition to alternative missions as they age. Technological Innovation • Digitalisation, data analytics, and arti cial intelligence – must be embraced to enhance predictive maintenance and proactive monitoring capabilities, improve asset tracking and management, and aid solid decisionmaking across the lifecycle. • Digital twin technology – a new evolving technology that by virtual representation of a system or a physical object holds immense potential for quantifying the impact of obsolescence and mitigation issues and strategies. • Obsolescence design innovation – develop modular designs with the use of open-source infrastructures to help expedite the replacement or upgrade of components as needed. Obsolescence considerations should be factored into the design of new components and oerings from the outset. Involving design experts early on in the process in cooperation with engineering units, suppliers, and other stakeholders. People • Collaborative partnerships - with industry partners and government agencies to share obsolescence methodologies and co-create for developing innovative solutions. • Supply chain collaboration – embrace strong communication and coordination between OEMs, suppliers, and end-users to ensure a cohesive approach to obsolescence management, and the sustainability of aircra. • Dedicated teams - establish a dedicated obsolescence management team responsible for tracking and addressing potential risks in a timely manner. Their role should include developing a replacement strategy, collaborating with suppliers, maintaining an obsolescence database, and strategic planning for obsolescence. • Educate employees – implement an ongoing training programme for the education of important best practice methodologies, and the maintenance of components. Include training schemes to educate employees on how to recognise counterfeit components. What signs to look out for when inspecting parts and how to spot fakes through comprehensive testing processes. Technological developments are pivotal in shaping the future of military aircra, oering transformative capabilities to enhance performance and eectiveness. To fully embrace and make the most of these technological advances organisations must not ignore the challenges of obsolescence management. A proactive and complete lifecycle approach is the only way to manage the ‘two-speed’ challenge for the long-term sustainability and operational agility of any military operation. https://milexia.com Giuseppe Bergamaschi, sales director of Milexia (above) Parts can risk obsolescence before the end of an aircraft’s service life (below)
www.aero-mag.com Aerospace Manufacturing May/June 2024 11 SPECIAL REPORT: MRO s JPB Système approaches its remarkable milestone of 30 years in business, I look back on a journey that has been marked by moments of triumph and adversity. At the same time, it’s apparent that from humble beginnings to becoming a prominent player within aerospace manufacturing, every step of our journey has been characterised by a willingness to take calculated risks, challenge the status quo, and seize opportunities for growth and advancement. A pinnacle moment for our industry and manufacturers like us was of course the Covid pandemic of four years ago. For my company, this rather inconveniently came at the very moment we commissioned a new state of the art production facility, and very shortly a er announcing two new product solutions. We’re o en put to the test, but it never seems to happen in the form or at the moment, we would prefer. Nevertheless, we dug in and while the world hit the brakes, we decided to keep our foot on the accelerator. Inspired by our country’s President, who as Covid struck, encouraged manufacturers to ‘be brave’, and trust that our government would support us, we proceeded with our ambitious plans. As we pressed on with construction of our new facility and drove forward with the new product solutions, we were also made some strategic supply chain moves around existing products. This saw us take the decision to overstock on materials so that we could react quicker upon the industry’s recovery. Although aware that the cash conversion would be degraded from the decision to over-stock ahead of the actual need, for us it about maintaining customer satisfaction and not losing business. At the same time, with the industry in freefall and with redundancies and furloughs commonplace across other companies throughout the manufacturing and supply chain, we managed to buck the trend. Not only did we retain every single person in our workforce, but we stuck with our recruitment eorts, on the assumption that sourcing skilled people would still be an ongoing issue (which has turned out to be accurate), even a er the pandemic was in the rearview mirror. Meanwhile, true to his word, our President didn’t desert us, and instead provided the nancial support he promised. In fact, for us, the move to continue our development of new product solutions and invest in manufacturing technologies like 3D printing to create them, paid o. Recognising that our own ambitions aligned with our government’s goals to support innovation and accelerate the transformation of key industry sectors, we were recently awarded funding to advance the development the technology solution for manufacturers that we previewed in 2019. With 60% growth since 2019 and over 60 new hires, 2024 sees us look proudly to the opening of our new production facility, which via an advanced Industry 4.0 enabled platform embodies our vision for the future and supports our drive to invent and diversify for decades to come. Looking back, we weathered the storm better than some, partly – I would like to think – by making wise business decisions and taking a few calculated risks, rather than mere happenchance or good fortune. Indeed, had we rushed to hit the pause button on Beta versions of new product solutions announced just prior to Covid, we would not have moved forward. This would not have seen us ultimately commercialise those solutions, which in turn would have likely had them not catch the eye of the government body responsible for awarding funding to companies they deem progressive and innovative. While neither my senior team nor I are out-and-out risk takers, there is nevertheless perhaps a certain amount of truth in the adage that fortune favours the brave. www.jpb-systeme.com In the wake of unprecedented challenges brought forth by the Covid-19 pandemic, the aerospace industry found itself navigating uncharted skies. Yet, during the turbulence, JPB Système dared to defy the odds. Here, company CEO, Damien Marc, explains that sometimes, it pays to be brave. A MISSION Damien Marc company CEO of JPB Système (above) Possible Scan here for more JPB Système articles
12 October 2013 www.aeromag.com May/June 2024 Aerospace Manufacturing www.aero-mag.com SPECIAL REPORT: CAREERS ago, having previously been a Lead Engineer within Project Tempest; the BAE Systems led mission to devise a route map for the UK to develop a home-grown, sixth generation combat aircraft. Project Tempest is not an aircraft… yet. It is a visioning process, a training camp, and an intelligence gathering exercise, A FRESH Chris Summers, Morson Projects’ Head of Engineering Delivery (above) t Morson projects, we deploy our expertise to deliver whatever project support our clients need, but our projects in the aerospace sector are really at the cutting edge of technologies and R&D. I took on the role of Head of Engineering Delivery less than a year focusing on what resources we can leverage and what capabilities we need in order to develop the combat aircraft of the future; from design, engineering, and manufacturing perspectives. It has been a privilege and an inspiration to be involved in Project Tempest. It has also been a reminder that we need to invest in fresh talent THINKING Chris Summers, Head of Engineering Delivery at multi-disciplinary engineering consultancy, Morson Projects, reects on the importance of the company’s Early Careers Development Programme (ECDP) in securing the new ways of working needed to reimagine aerospace engineering and drive genuine innovation. Complementing engineering skills with commercial, creative and collaborative attributes the aerospace industry needs (above)
Aerospace Manufacturing May/June 2024 13 - and more talent - if we are to deliver the ambition that sits at the heart of the project’s aims. A proud tradition The talent we recruit, nurture and develop now will be critical to achieving the results we need for the UK’s aerospace sector. In the UK, we have a proud tradition of aerospace engineering innovation, but that excellence must go hand in hand with the practicality and pragmatism needed to deliver solutions that are both world-class and commercially viable. The best engineered product is not the best solution if it is delivered late, over budget, or if it cannot be produced in volume. Engineering is all about optimal compromise – how do we achieve our goals within all the parameters set? The same principles need to apply to how we find, develop and deploy talent. We need to leverage the engineering expertise we already have, using that experience for both project delivery and mentoring new talent. But we also have to develop the digital natives coming into the sector, and benefit from a generation that not only accepts change, but anticipates, expects and embraces it. The UK’s engineering talent pool has been built on developing high achieving individuals with specific skills and roles. But if we’re aiming at a dynamic future, with new rules of engagement and a disruptor approach to innovation, creativity needs to be embedded at every touchpoint, including early careers recruitment and development pathways. I began my career as a stress engineer, but due to illness, without a first class honours degree or a Masters – the prerequisites that conventional industry wisdom dictates are the foundations of a successful career. I have developed as a multi-disciplinary professional, becoming Chartered, leading teams and winning multiple industry awards, most recently a BAE Chairman’s Award – proving that what makes a successful engineer is not simply the level of attainment they can bring to the job; but also the level of ambition, enthusiasm, and commitment they can offer. Those are principles that lie at the heart of our Early Careers Development Programme at Morson Projects. We’re looking for the very best future engineers, but we’re not limiting ourselves to how they look on paper – we’re looking at the whole person. Who can we find who is passionate about what they do? Which candidates will ask questions? Think differently? Collaborate? Approach a problem by looking for the optimal compromise rather than labouring it beyond budget and viability? Our ECDP is not measured in time, but in milestones. We encourage our engineers to learn from mentors and each other. We get them involved in projects from their first days with the company and challenge them to gain the multi-disciplinary skills and knowledge they need to advance both their careers and our projects. Not all the milestones they need to achieve are technical competencies because project delivery is a much wider remit. One of the ECDP engineers on my team is a great example of those principles. She doesn’t have a degree in aerospace engineering; she studied robotics. But she wanted to work in aerospace. So she tracked me down at a conference and asked me to be her mentor. That’s the kind of ambition and commitment you can’t teach. I’m confident that we have the best trainers and the most robust, innovative ECDP in the engineering sector at Morson Projects. I also think that, as a company and a leadership team, we’re pioneering an approach to complementing core engineering skills with the wider commercial, creative and collaborative attributes the aerospace industry needs. On a current project, I’m working with Morson Projects engineers based out of our Manchester, Bristol and Belfast offices – digital working opens up a new world of multidisciplinary collaboration and it’s exciting to see where our 40-years’ experience and pool of new talent can take us. https://morson-projects.co.uk We’re looking for the very best future engineers, but we’re not limiting ourselves to how they look on paper – we’re looking at the whole person. WE LIVE QUALITY TOOLING FOR APPLICATIONS WHERE CHIP BREAKING IS AN ISSUE HIGH POSITIVE, GROUND AND POLISHED TURNING INSERTS: • Over 1000 options of precision periphery ground high positive inserts • 5 different chipbreaker geometries • Nose – radii from 0.05 to 3.0mm • Choice of non-coated and coated carbide grades • AD2 diamond coated grade for glass reinforced plastic (GRP) materials • Each insert 100% inspected for absolute top quality results. • Also, high precision ground inserts with cutting edge preparation for high temperature alloy machining. © ARNO-2024-05-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 Download the whole catalogue at: ARNO.de
14 October 2013 www.aeromag.com May/June 2024 Aerospace Manufacturing www.aero-mag.com SPECIAL REPORT: COMPONENT CLEANING ecWash Systems, a pioneer in industrial parts washing technology, is celebrating its 30th anniversary. This marks an exceptional journey of innovation, customer focus and commitment to excellence. During this period the company has established itself as a global leader in providing bespoke aqueous parts washing solutions to meet the most stringent demands of manufacturers. Working alongside some of the most prominent names in manufacturing, MecWash has developed component cleaning systems for the most complex applications. The UK-based manufacturer has built unique insight and expertise for solving cleaning challenges across a spectrum of industries. MecWash originated as a spin o from an impregnation business and was started by Paul and Steven Young, in 1993. Originally based in Gloucester, the business moved to Tewkesbury in 1998 and then relocated to the other side of the M5 junction in 2005 to its current facility. John Pattison acquired the business and became managing director in 2008 and has overseen the growth and the progress of the technology since then. “I am delighted to be part of the MecWash story, and I am excited to see the opportunities for MecWash to develop over the coming years,” states Pattison. “There have been challenging periods of economic uncertainty during my tenure, but MecWash is stronger than ever. “We think that 30 years is a sign of maturity and it’s remarkable to see what MecWash has achieved. Our bespoke parts washing systems are now used by the world’s leading manufacturers. We are condent of building on our success over the decades to come.” The company’s commitment to sustainability is evident in its focus on aqueous systems, designing and manufacturing durable machines with minimal environmental impact. MecWash machines are built to withstand the rigors of demanding industrial environments, ensuring years of reliable performance. Part cleaning evolution Aqueous washing has progressed enormously during MecWash’s lifespan. Thirty years ago, solvent systems were ubiquitous in industry and many engineers were very wary of aqueous cleaning. This has changed substantially with many major manufacturers solely relying on aqueous cleaning and solvents being avoided wherever possible due to environmental and H&S concerns and the regulatory burden. This evolution was partly driven by environmental regulations such as the EU Solvent Emissions Directive, causing a surge in demand for aqueous washers. It was also aided by the substantial improvements in aqueous washing chemistry and technology. MecWash has played a key role in the development of the UK aqueous washing industry, consistently pushing the boundaries and developing sophisticated precision parts washing machines. This year is particularly special for industrial parts cleaning system specialist, MecWash Systems as it marks the company’s 30th anniversary – a signicant milestone that underscores three decades of innovation, quality and commitment to excellence in the parts cleaning industry. M PARTS CLEANING MecWash is committed to sustainability with its focus on environmentally focused aqueous systems (above) Excellence Scan here for more MecWash articles
www.aero-mag.com Aerospace Manufacturing May/June 2024 15 The rst machine produced by MecWash was the MPS. The Mini, Midi and Maxi systems (small medium and large sizes) followed shortly aer. These machines oered spray and ood washing, plus rinsing and hot air drying. In 2006, the Solo was rst produced as a cost-eective spray only interstage washer, before the mid-market general purpose Duo system was added in 2007. In recent years the Mini, Midi, and Maxi have been modernised to the MWX300, MWX400 and MWX600. These machines incorporate greater functionality, easier maintenance and the latest connectivity, for ‘talking’ to customer systems or for cloud connections. “MecWash machines have developed considerably over the last three decades,” Pattison explains. “Today, the design, build and maintenance of the systems are very sophisticated, just like the components they are designed for. We understand the manufacturer’s process end-to-end and the dierent applications that require cleaning. System integration is part of the MecWash story. It’s vital that each system in the range integrates AEROSPACE CLEANLINESS WITHOUT SKY-HIGH COSTS. VALUE AND PRODUCTIVITY WITH MECWASH. Machined castings. Turned parts. Complex pressings and extrusions. Customers expect parts to be pristine. PRECISION AQUEOUS CLEANING demands MecWash. From small cell based units to sophisticated systems, from interim wash to final specification, MecWash have a system to meet your requirements and your budget - all with the renowned MecWash quality and reliability. • IMMERSION & ROTATION • TARGETED JETTING • ULTRASONIC AGITATION • VACUUM DRYING TRUSTED BY NAMES LIKE... • Renishaw • JCB Cost-effective. Sustainable. Reliable. For the best wash machine solution for your production line, talk to MecWash. Contact us today on 01684 271600 or visit www.mecwash.com Designed and manufactured in Britain YOUR EXPERTS IN COMPONENT CLEANING • Rolls Royce • BAE Systems • Collins Aerospace • Parker Hannifin • Perkins • Meggitt • JLR • Husco seamlessly with other handling and ancillary equipment. Each MecWash installation is tailored to meet precise requirements of the customer.” In addition to process and machine building skills, the team possess an unparalleled understanding of cleaning chemistry. MecWash has invested in its own laboratory at its headquarters in Tewkesbury. The site is purpose built to design, develop and formulate chemicals for common and bespoke component cleaning applications. “Our expertise in wash chemistry is based on years of experience tailoring chemicals for the most testing wash challenges for individual customers, as well as manufacturing our own range of general wash chemicals and inhibitors,” concludes Pattison. “It’s this fullyrounded knowledge of all aspects of cleaning that enhances the analysis and insight our team provides, which gives MecWash the edge. Customers contact the MecWash team to nd a solution to their most dicult cleaning issues, components with complex geometries, challenging substrates or tenacious contaminants.” MecWash understands that a manufacturing process is only as strong as its weakest link. The company strives to ensure that its cleaning technology embraces and supports the progress of intelligent manufacturing, continuing to provide enhanced eciency, reliability, integration and quality for the manufacturer. www.mecwash.com The MecWash bespoke parts washing systems are now used by leading manufacturers (above)
MACHINING TECHNIQUES: ADDITIVE MANUFACTURING 16 May/June 2024 Aerospace Manufacturing www.aero-mag.com dditive Manufacturing (AM) has evolved from prototyping with basic materials and equipment to producing low tolerance components with limited use to AM as we know it today. That is a highly complex, high accuracy production technology which is rapidly impacting several industries in which it competes as a viable alternative to traditional chip-cutting or injection moulding methods. The evolution of hardware and so ware is quickly removing barriers and enabling machine builders and machine users to adopt AM technologies in their factories and on their shop oors. It represents a signi cant development on the road to digitalisation. AM opens myriad opportunities for manufacturers. Companies can reimagine their products with reduced weight and material consumption. They can realise a digital transition from scan to part. Further, they can rethink their business or reinvent their manufacturing. Product transformation happens by moving from conventional designs to a design specically for AM. Other realities quickly become apparent, as well, including the ability to produce one-os in a practical and cost-eective manner, maintain zero inventory in certain industries with on-demand production, adopt a designanywhere, print-anywhere mindset and accelerate innovation cycles. Finally, a company can eliminate moulds, castings and tooling, eliminate or drastically reduce assembly processes, reduce supply chains and move to a exible, low-volume production landscape at workable margins. AM has accelerated innovation by taking it to the next level. With 3D printing, a manufacturer can quickly get the part in their hands and can see it in form, t and function modes. They can make an adaptation and quickly print it again. Additive has reinvented manufacturing by eliminating mouldings, castings and tooling, in most applications. Printed out as one A recent example is an aviation fuel injector. This project took several years, but started with 21 individual machined cast and fabricated components that were welded and braced together to create a fuel nozzle and injector. Today, the fuel injector is printed out as one component on an additive manufacturing machine. It simplies the assembly process, radically improves quality, reduces inventory and changes the supply chain in fundamental ways. This is an excellent example of additive acting as a ‘disruptive’ technology. A poor choice of word, perhaps, because of its pejorative nature. However, that is precisely the description which ts, as additive impacts the entire process of part concept, design, manufacture and assembly, whether that part is injection moulded plastic, cast base metal or machined superalloy. The additive process started out very complex, requiring many steps that occurred in a silo mentality, with multiple types of soware and individual workstations for design, simulation, print prep, actual additive manufacturing, heat treat and nishing/inspection. Recent advances in digitalisation today allow a fully digital and far more cost-eective, endto-end solution. Starting with the virtual product, or the digital twin, then the virtual production, which is the digital twin production, to the real automation, which is the real machine doing its work. A closed loop digital chain can link all these functions together and keep them in one solid package. It can also collect performance data at every step, realise the data, optimise it and have it resident on one collaboration platform with a solid industrial ring of security. This model provides a great value to the manufacturer by taking real product feedback performance data and feeding that data directly back into the original CAD model of the design. By simulating it throughout the entire process for validation, this model can be simultaneously predicting manufacturing and even assembly challenges, adjusting the design as needed to compensate. To speed up the utilisation of AM for a company, identify a champion at your company who is familiar with both your operation and the additive world. Lean on their strength and commitment to improve your company and better position it to remain innovative and competitive in today’s changing marketplace. www.siemens.com/aerospace Steve Vosmik head of the Additive Manufacturing Centre of Competence, Siemens Industry, examines the role of digitalisation and additive manufacturing, and how best to leverage the real and virtual worlds. A BETWEEN THE REAL AND VIRTUAL WORLDS AM accelerates innovation by taking it to the next level (above) Scan here for more Siemens articles
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
ADVANCED MATERIALS: COATINGS 18 May/June 2024 Aerospace Manufacturing www.aero-mag.com n aerospace manufacturing, the repair and maintenance of key aircra components emerge as pillars of resilience and innovation. The commitment to leveraging cutting-edge technologies to re ne repair processes is crucial in ensuring the industry’s commitment to excellence, safety, and sustainability. The defence and military sector is a substantial consumer of aerospace parts. Governments worldwide allocate resources to bolster defence expenditures, strengthen national security, and sustain military prowess. This drives the requirement for aerospace parts across various military platforms, including aircra , helicopters, missiles, and other defence systems. In addition to the continuous advancements in aerospace technologies, you can see why the industry is continually growing. To ensure that components uphold the highest standard, having Federal Aviation Administration (FAA) is essential as it validates that their products or processes comply with FAA regulations and are safe for use in the national airspace system. Additionally, Nadcap accreditation serves as a hallmark of excellence in manufacturing. Achieving Nadcap accreditation demonstrates a company’s commitment to quality, process control, and continuous improvement, instilling customer con dence and fostering trust within the industry. Recently, SIFCO ASC’s facility in Texas has achieved both accreditations, further strengthening our commitment to improving the aerospace and defence industry. To accomplish these industry milestones, we went through an application process, pre-assessments, and an extensive on-site audit of our facility’s operations, methods, and quality management systems. Each involves rigorous testing, evaluation, and documentation to demonstrate compliance with airworthiness standards, design requirements, performance criteria and operational guidelines. Surface nishing evolution Selective electroplating has been an integral component of aerospace surface nishing for decades. By oering a precise, localised plating process, technicians can enhance components directly on the aircra . Unlike conventional plating methods, which involve immersing entire parts into plating solutions, SIFCO ASC allows targeted plating on speci c areas without disassembly. This selective approach minimises material waste, reduces processing time, and preserves the integrity of the components. One of the main advantages of the ‘SIFCO Process’ is its portability, which enables our team of expert technicians to deliver services directly to our customers’ sites in the eld. Brush plating can occur in hangars on grounded aircra without disassembling parts and shipping them out. We can also travel to military bases to do the necessary work within the defence sector, providing convenient and ecient plating solutions. The recent accreditations gives us a greater advantage in supporting the aerospace industry with selective electroplating applications. Certi ed FAA-approved repairers can deposit plating materials precisely only where needed, ensuring optimal coverage and minimal material waste. Using the SIFCO Process oers several bene ts for aerospace components. The corrosionresistant and conductive properties of selective electroplating extend the service life of critical aerospace components, improving reliability and safety. There is no longer a need for complete component replacement; SIFCO ASC plating oers a cost-eective alternative for repairing and refurbishing aerospace parts. Additionally, SIFCO ASC’s selective plating process reduces chemical usage and waste generation compared to traditional plating methods, aligning with the aerospace industry’s sustainability goals. Elevating excellence The aerospace industry is poised for further innovation and advancement in surface nishing technologies. SIFCO ASC continues to invest in research and development, exploring novel materials, processes, and applications to address evolving industry needs. Emerging trends such as additive manufacturing and advanced materials present new opportunities for enhancing aerospace surface properties. By integrating SIFCO ASC’s selective plating expertise with cuttingedge manufacturing techniques, engineers can unlock unprecedented levels of performance, eciency, and sustainability in aerospace systems. In aerospace engineering, surface nishing technologies are critical in enhancing component performance, reliability and longevity. The SIFCO ASC plating process represents a paradigm shi in selective electroplating, oering precision, versatility, and environmental sustainability unmatched by traditional methods. With our recent FAA approval, SIFCO ASC rearms its position as a trusted partner in the aerospace industry, setting new standards for quality, reliability, and innovation. As aerospace manufacturers and operators embrace advanced surface nishing solutions, the journey towards safer, more ecient, and sustainable aviation reaches new heights, propelled by the relentless pursuit of excellence and ingenuity. www.sifcoasc.com Lillian Smereczynsky, quality manager, SIFCO ASC, explores the requirements of aviation authorities, ensuring that every component repair upholds the highest airworthiness and passenger safety standards. I ADVANCING AEROSPACE EXCELLENCE Lillian Smereczynsky, quality manager, SIFCO ASC (above) Scan here for more SIFCO articles SIFCO ASC plating offers a costeffective alternative for repairing and refurbishing parts (top right)
RkJQdWJsaXNoZXIy MjQ0NzM=