1 October 2013 www.aeromag.com www.aero-mag.com THE EUROPEAN MAGAZINE FOR A GLOBAL INDUSTRY CIVIL & DEFENCE/SPACE/SUPPLY CHAIN SEPTEMBER 2023 EVENTS PREVIEW DSEI 2023: ACHIEVING AN INTEGRATED FORCE Page 30
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A head for heights 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 AIRCRAFT PROGRAMMES 8 A complete, blended solution – Helicopters TECHNOLOGY FEATURE 12 A new industry standard – Interiors ADVANCED MATERIALS 14 Ingenuity in the material mix – Composites 18 Supply and demand – Machining techniques SUPPLY CHAIN 20 A change for the better – Digitalisation DIGITAL MANUFACTURING 22 More than just cutting shapes – Industry 4.0 EVENTS 25 Get ready to innovate! – EMO show preview 30 DSEI 2023: achieving an integrated force – DSEI show preview 32 Uniting the entire metals supply chain – UK Metals Expo preview FINAL APPROACH 34 Leading the charge – Foster Ferguson, global director of aerospace, Stratasys Next issue: Events: Advanced Engineering, Space programmes, Technology feature: Landing gear, Materials: Test & measurement, Special report: Surface finishing, Supply chain: Procurement, Digital manufacturing: Simulation, Final approach As the old saying goes, what goes up must come down. Witness the latest crop of static attention-grabbing eVTOL aircraft on display at the recent Paris Airshow. With the curves and lines more akin to sportscar designs, I was filled not only with a sense of deep awe for the innovative technologies in front of me, but deep rumbling in the pit of my stomach, like that experienced during an extremely bumpy passenger flight. It brought to mind another old saying along the lines of you’ll never get me up in one of those things again. In terms of airworthiness, they looked… fragile to my eyes at least, and would seem more at home in the latest science fiction film. I’m sure someone reading this will put me right and one day offer me a test flight in one. To which I will politely decline. When I was a young boy I used to climb the tallest tree and happily perch on the highest branch without any fear whatsoever. Now, with the march of time, I find a trip to the top of any tall building quite taxing to say the least. I think I’ve lost my nerve - I even get nervous when my son flies off on holiday somewhere. Which brings me to a lovely story doing the rounds in the press lately. A father-daughter duo are keeping it in the family after operating a Jet2.com flight together for the first time. Brian and Becky Morgan made a memory that they will cherish forever after operating the full flight together from London Stansted to Tenerife – a dream that they have had for years. It might seem an odd thing for the editor of an aerospace magazine to say, but for now at least, I’m keeping both feet firmly on the ground. Mike Richardson, editor ISSN 2056-3434 www.aero-mag.com Aerospace Manufacturing September 2023 3 COMMENT & CONTENTS Volume 18 Issue 169
4 October 2013 www.aeromag.com NEWS September 2023 Aerospace Manufacturing www.aero-mag.com Francis Brown secures JOSCAR accreditation Francis Brown has gained a place on JOSCAR, the Joint Supply Chain Accreditation Register. By achieving this accreditation, the company has demonstrated its ability to meet the stringent requirements of purchasers within the sector. In addition, it also achieved Cyber Essentials Plus accreditation, the scheme’s highest level of certification which involves the rigorous testing of its cyber security systems. Jamie Brown, CEO of Francis Brown, said: “Both accreditations signal this company’s commitment to maintaining the highest standards of quality, security, and client satisfaction. Francis Brown already operates in the defence sector, but JOSCAR is a significant stamp of approval in terms of reliability and quality. It also provides huge opportunities by highlighting our capabilities to the many world-leading businesses which use this accreditation system.” www.francisbrown.co.uk ASG Tooling has announced a recent major contract award win with Airbus worth $2.4 million. Under this agreement, the company will be responsible for the design, fabrication, and machining of bespoke shipping containers. The project encompasses a 12-month lead-time during which ASG Tooling will incorporate design changes and manufacture the containers at its Manchester-based facilities. ASG Tooling’s group managing director, Simon Weston (pictured), commented: “Winning this contract with Airbus is a testament to ASG Tooling’s commitment to excellence and our ability to deliver cutting-edge solutions. We are honoured to have been chosen as their partner and are confident in our ability to meet their unique shipping container requirements.” The bespoke shipping containers, over 18m in length, are designed to meet Airbus’s specific needs to transport major airframe assemblies using bespoke quality jigs and workholding and will undergo an extensive fabrication and machining process, including hydraulics, air-conditioning and electrical lighting. Once manufactured, the shipping containers will be transported to Hamburg where they will be assembled and rigorously tested in accordance with Airbus’s stringent quality standards. www.asg-group.co ASG Tooling signs new Airbus deal Hyde Aero Products has announced its involvement with the I-Break (Landing Gear Industrial Breakthroughs) project. Hyde Aero Products is part of the £22.5 million collaboration between 16 partners, including industry leaders to small businesses, academics, and research organisations. It will, for the first time develop and manufacture major landing gear structural components currently produced using large forgings, with innovative techniques - such as powder hot isostatic pressing, additive manufacture and composite materials - in order to reduce the aircraft time to market and reduce industrial CO2 footprint by 30%. www.hydegroup.com Hyde joins £22.5m I-Break project
www.aero-mag.com Aerospace Manufacturing September 2023 5 Dust in Composite Manufacturing Any engineering firm working with composites is likely to produce potentially hazardous dust. Our centralised dust extraction systems work by capturing dust at the source of the process before air contamination. Using a high velocity vacuum, with a range of bespoke collection and containment methods, ensures a healthy environment for workers in this industry. With over 37 years’ experience, our own installers and servicing engineers, combined with a renowned reliable product, will give you the best solution. Contact us now for a free consultation. +44 (0) 1788 890571 enquiries@mindensystems.co.uk www.minden.co.uk Global Urban & Advanced Air Summit (GUAAS) Asia has announced its futurefocused agenda and three plenary themes for its upcoming instalment in Singapore. Taking place 27-28 September 2023 at Marina Bay Sands, Singapore, GUAAS is recognised as one of the leading Advanced Air Mobility (AAM) and eVTOL global business events to attend. Developed and organised by the team behind the Farnborough International Airshow, GUAAS Asia 2023 will consist of a two-day programme bringing together the Asia Pacific AAM and Urban Air Vehicles (UAV) community. The conference programme will be split into three forward-looking plenaries, covering tactical strategies, AAM market positioning, UAV and drone use cases, technology vulnerabilities and solutions: Asia Pacific, when will the AAM ‘sleeping tigers’ wake? a market deep dive; con-ops – flying safely & securely; and current and future use cases. The agenda will feature keynotes and panel discussions aimed to future-proof the global AAM sector, as well as the Investor Business Connections Exchange, designed specifically for investors who wish to learn and enhance knowledge around UAV and AAM, and seek exciting investment opportunities in this growing aerospace sector. www.farnboroughinternational.org GUAAS Asia announces future-focused agenda AMETEK makes Bentley appointment AMETEK MRO Muirhead Avionics has appointed David Bentley as vice-president & business unit manager in the UK. He was previously responsible for AMETEK MRO’s businesses in the American Midwest. Bentley’s focus is firmly centred on operational expenditure, and he will bring this expertise to the fore as he joins Muirhead Avionics at a dynamic time in the company’s history. “The Muirhead Avionics business has an impressive 73-year history,” said Bentley (below). “Our customer base is robust and we have experience on more than 7,000 avionic control components over a wide range of the world’s aircraft types including: instruments/indicators, weather and mission radar, audio and cockpit controls, ground support equipment, repair management, navigation and communication aids, flight data & cockpit recorder analysis and repair.” AMETEK MRO Avtech will shortly be relocating its Florida business to the UK and this will fall under Bentley’s remit. The Muirhead Avionics facility will soon be moving from its current location to a large high-tech new facility close to London Heathrow. www.ametekmro.com Airbus Helicopters and HVM Catapult sign MOU Airbus Helicopters UK has signed a Memorandum of Understanding (MOU) with the High Value Manufacturing (HVM) Catapult. This strategic partnership will see both organisations establish a framework under which they will jointly investigate opportunities to work together on future opportunities. “The collaboration will enable us to leverage our capabilities in manufacturing research and development across our seven centres to enhance the competitiveness of the helicopter sector,” stated Katherine Bennett, CEO of HVM Catapult. “Together, and with support from Innovate UK, we will push the boundaries of what is possible and shape the future of helicopter manufacturing in the UK.” Based at Oxford Airport, Airbus Helicopters in the UK provides the entire UK police helicopter fleet, two-thirds of the country’s air ambulance fleet and most of its overall civil helicopter fleet. www.hvm.catapult.org.uk L-R: CEO HVM Catapult, Katherine Bennett; managing director Airbus Helicopters in the UK, Lenny Brown; head of material and vehicles R&T, Airbus Helicopters, Delphine Allehaux
6 October 2013 www.aeromag.com NEWS Xxxxxxxx 2014 www.aeromag.com At a time when employee retention is proving a great challenge for the manufacturing sector, coatings specialist, Indestructible Paint is celebrating a special milestone – a quarter of its team have now been with the family-owned company over 25 years. Indestructible Paint thanked the latest nine employees who have most recently reached 25 years of dedicated service. The loyal team are instrumental in delivering great results across every level of the business from production to sales to senior management. They are the company’s greatest pride. “We’re proud to have a knowledgeable, skilled and loyal team making up the Indestructible Paint family,” said managing director, Brian Norton. “Investing in training and development over the years is invaluable for both our people and our business. As the company grows and orders pour in, it makes a big difference to have such a dependable team to deliver for our customers and develop innovative solutions for the future.” https://indestructible.co.uk Loyalty is the winning formula Dassault Aviation has become a subscribing member of the Nadcap Accreditation programme. Nadcap Subscribers are aerospace prime contractors who have demonstrated design authority and control over supplier quality throughout their organisation. Jim Lewis, vice-president of Nadcap, said: “We appreciate the wealth of experience and expertise that Dassault Aviation brings to the Nadcap programme, and look forward to working collaboratively with the company, to improve quality in critical manufacturing processes within the aerospace industry, and to ensure the safety of passengers.” www.p-r-i.org Dassault Aviation subscribes to Nadcap Rafale, Falcon and the Patrouille de France. Credit: Dassault Aviation – A. Pecchi
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8 October 2013 www.aeromag.com September 2023 Aerospace Manufacturing www.aero-mag.com AIRCRAFT PROGRAMMES: HELICOPTERS t’s been a tumultuous start to the decade for the helicopter industry. After the sharp downturn prompted by Covid, supply difficulties and continuing skills shortages across the delivery chain present ongoing challenges in a sector driven by advanced technology and reliant on an agile response to mission critical, commercially sensitive and contracts delivered to tight timeframes. A survey carried out by the ADS Group earlier this year revealed that 75% of the organisation’s members are concerned that workforce and skills shortages are significantly affecting their business, prompting an urgent need to develop robust and creative talent strategies for both current and future skills needs. The challenge for helicopter manufacturers is not just sourcing the required talent in the right locations in a sector where skills profiles are rapidly evolving; it’s also the need to up-scale, downsize and tailor the team to the needs of projects and contracts in realtime. As with any sector where specialist knowledge and experience is critical to the success of project-based work, a conventional approach to recruitment could involve potential delays running into several months as a manufacturer defines, identifies, interviews and vets potential team members, then onboards everyone and establishes a new team dynamic as the project gets underway. It inevitably involves competing for skilled and experienced individuals too, and potentially the need for targeted upskilling to tailor the available resource to the task in hand. This approach is at odds with the demands of a sector that often requires project delivery to strict deadlines and the highest engineering standards of safety and performance. For these reasons, Leonardo and Morson Projects have signed a long-term strategic partnering agreement (SPA), which will enable the UK’s only onshore helicopter manufacturer to offload engineering work to augment the company’s existing highly skilled engineering capacity. The new agreement continues a relationship between the helicopter manufacturer and the engineering design consultancy specialist that is now entering its third decade. Morson Projects will be managing engineering work at Leonardo’s UK helicopter facility in the South West of England through the management of fixed-price packages at one of Morson Project’s UK design offices in Northern Ireland and the North of England, covering Belfast, Manchester, and Hull. Morson Projects’ specialist engineering group enables manufacturers such as Leonardo to tap into the resource of trained and experienced engineers who are fully employed by Morson and able to provide skills across a wide range of relevant disciplines. Where necessary, Morson can also leverage its pool of engineering contractors, while also looking ahead to the future needs of the industry with its early careers development programme. “This strategic partnering agreement helps to secure our engineering work Engineering design consultancy specialist, Morson Projects reveals how it is helping Leonardo’s South West of England helicopter facility to take flight by using an outsourced approach to high-flying talent. I A COMPLETE, BLENDED The agreement enables Leonardo to offload engineering work to augment its existing skilled engineering capacity (above) Solution
www.aero-mag.com Aerospace Manufacturing September 2023 9 and supply chain resilience across the UK,” says Adam Clarke, managing director of Leonardo Helicopters UK. “If we are successful on large contracts like the UK MOD New Medium Helicopter programme, the partnership means we will have a number of skills available to us to support UK prosperity and our engineering ecosystem.” A blended approach The engineers that Morson Projects supplies into the helicopter sector provide a complete, blended solution for manufacturers with the ability to cherry-pick optimised teams across specialist disciplines, from design engineers through to stress engineers, fatigue engineers, software developers and avionics specialists. Working closely with the client to understand the scope of activity and the work required, Morson Projects draws talent from both retained and contractor engineering teams, from across the UK and Italy, to provide the right blend of knowledge and experience for the specific requirements of the contract. Becky Veal, associate director – engineering delivery at Morson Projects explains: “We are certified as a Gold employer by the government’s Defence Employer Recognition Scheme and many of our engineers are exarmed services personnel. They may have 20 years’ experience of working on an aircraft, so they are already familiar with the manufacturer’s operating systems and development platforms, enabling them to hit the ground running as soon as they are deployed for a role. “Some of the roles we supply may require the engineer to work on site with Leonardo two or three days a week, others might be home-based, or involve working from one of our offices, where we have experienced work zones to facilitate knowledge sharing and collaboration within project teams, while ensuring confidentiality is never compromised.” Identifying new talent With unprecedented levels of demand for engineering talent, both in the UK and around the world, Morson Projects’ engineering delivery capabilities provide a flexible approach to resourcing projects so clients can be more agile in ramping up or winding down project teams, with a more nimble and dynamic onboarding process. The talent pool that Morson Projects can provide is already specialist in aviation and defence, so the need for confidentiality is ingrained in their working culture, and newly appointed teams will often have worked together before. Scan here for more Morson articles But the task of improving resilience in project resourcing for clients like Leonardo goes beyond providing immediate access to a broad range of engineering disciplines and experienced personnel. Morson Projects also operates an Early Careers Development Programme, designed to generate a pipeline of future talent by nurturing graduate and apprentice resource. Head of engineering project delivery at Morson Projects, Matthew Thompson, comments: “We pride ourselves on our commitment to supporting the professional and personal development of all our employees and our Early Careers Development Programme allows us to lead the way in growing the UK’s top engineering talent of the future, supported by our in-house operational enabling teams. We began this year with 62 early careers employees within our engineering team, and we plan to increase this by another 40% over the next 12 months, all of whom will be supported by our trained, in-house mentors. Apprenticeships last for up to four years and Morson Projects offers apprentices experience across a wide range of disciplines, which both provides them with a grounding in the interdependency of various elements of the project delivery process, and enables them to make an informed choice about where they want to specialise. Each apprentice is trained and mentored in-house by Morson Projects’ experienced teams, and the company also works with i-Aero in Yeovil to train budding engineers and upskill those who want to broaden their experience or exploit transferrable skills. Reviving the talent pool With a strong heritage of helicopter manufacturing in the UK, there is an excellent pool of expertise in the sector; but there is also substantial, global competition for talent. Outsourcing engineering resource to a partner like Morson Projects, with UK and European offices, a footprint in Australia and a tier-two supply chain in key markets such as India, enables companies like Leonardo to avoid problematic peaks in demand for skills and bid for contracts with a high level of certainty that they will be able to resource them. “For some time, the engineering talent pool has been running dry,” adds Thompson. “So there has been a need for fresh thinking and a different way of working. Our approach has been to address this issue from multiple standpoints, providing flexibility with a plug and play solution for existing talent, while bringing in skills from other sectors, training those with transferrable skills and nurturing the next generation. It’s a holistic response that would be too cumbersome for a lean manufacturer to invest in alone, but works as an outsourced solution for our manufacturing clients because it draws on the engineering, recruitment and training resource within the Morson Group.” https://morson-group.com Becky Veal and Matthew Thompson of Morson Projects (left) There is an excellent pool of expertise in the UK helicopter manufacturing sector (below)
Torus’ Boring Machine makes light work of fan cases The A521 has the capability of machining complete or even partially re-lined fan cases, of all engine types with minimal tooling change requirements, utilising fewer personnel, producing a more accurate profile than traditional methods in a fraction of the time. The A521 Fan Track Boring Machine features CNC cutting path negating the need for expensive fixed profile templates prone to inaccuracy and wear. Additionally, cutting profiles can be easily produced from the fan tracks CAD files giving unprecedented flexibility, dramatically reducing lead time and costs for new profile variants. The integrated measurement system is utilised for pre-machining inspection optimising the cutting sequence to provide ultimate machining efficiency. Once the machining is complete, the measurement system automatically conducts a full inspection, producing a measurement report tailored to the end users’ requirements which include full profile scanning, multiple gauge point measurement and full radial scanning. These reports, not only ensure total traceability for all machined engines, but also mean that the Leading and Trailing edge fan-tip clearance check, becomes a single operation, where as previously, this laborious process may have been repeated two or three times before the fan track was cut to size. Furthermore, the fan-track can be ‘reverse’ engineered to suit the fan-set, optimising efficiency, not only of the process but of the airflow and ultimately fuel burn. FEATURES: • Capable of machining partial fan tracks (maybe required at overhaul) & full fan tracks (typical to engine production). • There is also the facility to custom cut profile diameter to match the fan set. • Integrated vacuum extraction system removes dust directly from the cutting tip, leaving the working environment free from contamination, meaning that the cutting operation can be conducted in the engine build area. • Transportable through the factory once folded away into its compact position on the wheeled base. • All interlocked guarding is integrated within the trolley, and once machine is located, is quickly & easily positioned. • Loading of the machine onto the engine is effortless; the pneumatic manipulator is balanced to give the boring bar an almost weightless feel. This of course, also ensures there are minimal external forces on the LP shaft or through the fan case during machining. Contact Torus Measurement Systems directly for further information: tms.sales@torus-group.com | www.torus-group.com Maintaining fuel efficiency throughout the Turbo Fan engines life is vital to the operators. With this in mind, Torus Group developed the A521 CNC Fan Track Boring Machine. The machine is currently in operation, in both Production and MRO Facilities globally. measurement systems
metrology manufacturing www.torus-group.com Torus Metrology Torus Manufacturing Our experienced team provide design & precision machining services to the aerospace industry throughout the UK & Internationally. Torus Metrology can handle your Aerospace headaches with our experienced Metrology engineers able to offer comprehensive and cost effective solutions. Our state of the art Toolroom provides a range of engineering solutions. With more than 25 years experience in toolmaking, whether you require a turnkey or high volume manufacturing solutions, you can be assured Torus Manufacturing has the answer - CMM Sub-Contract Inspection - CMM Software Training - CMM Programming Support/Cover - UKAS Calibration of Artefacts, Jigs and Ref Items - Measurement Correlation Support - FAIR, ISIR, LAIR, FOIR, IPIR, PPAP tml.sales@torus-group.com tms.inspection@torus-group.com
12 October 2013 www.aeromag.com September 2023 Aerospace Manufacturing www.aero-mag.com TECHNOLOGY FEATURE: INTERIORS very single piece and part of an aircraft represents an opportunity to increase performance and function, reduce weight and environmental impact, and to save money. Weight, cost, performance, and more recently sustainability are key metrics that drive research, design, and innovation in the aerospace manufacturing space. Often, there is a trade-off when balancing and applying these metrics and it can be difficult to improve one area without sacrificing another – lower cost could mean lower quality, more sustainable could mean more expensive. There is a reason the idiom “You get what you pay for” persists. However, recent advances in composites and additive manufacturing (AM) are challenging that notion; a new standard in the design and manufacture of current and future aerospace parts is on the horizon and within reach. A key player and innovator in this sector is Switzerland-based 9T Labs, who have defined Additive Fusion Technology (AFT), a new and emerging standard in hybrid manufacturing that opens new possibilities for continuous fibre performance when dealing with very intricate and structurally loaded components. Innovative developments in software and hardware allow AFT to deliver composite products that compete with traditional subtractive manufacturing and machined metal components on cost, weight, performance and sustainability. An incredible potential In practical terms, this means lighter, stronger and cost competitive parts that produce zero waste and even allow the use of composite waste as one feedstock source. For these reasons, AFT has incredible potential across multiple industries, including aerospace. The novel and automated multi-step process that is AFT uses integrated software in concert with precision AM processes and advanced postprocessing that leverage a Build Module and a Fusion Module that work seamlessly together. The software can easily import CAD files for templates and optimise structural calculations to make sure the right amount of material is placed exactly where it is needed. The Build Module, an open material platform, takes the optimised part design from the software and implements an AM process that uses two material deposition guides to place thermoplastic filaments alongside unidirectional (UD) continuous fibrereinforced tapes. In the final step of AFT, the Fusion Module applies heat and pressure to fuse the preform parts with a fibre volume ratio of up to 60% in a mould. This process allows for a low void content (<1%), maximum interlaminar strength, metal parts integration, and reshaping. Automating the process of composite manufacturing the way AFT does allows for the quick and efficient production (volumes between 1,000 and 100,000 parts per year) of relatively small, strong parts that are cost competitive, lighter and more sustainable when compared to traditional metal parts. Specifically, AFT solves the problem of scrap waste that persists in most subtractive manufacturing processes, including those used to create metal parts. Using a hybrid manufacturing approach like AFT not only enables a zero-waste starting point, but it also offers an end-of-life recycling opportunity that keeps the raw materials viable through multiple lifecycles. When compared to aluminium, the AFT process decreases part weight by about half, yet maintains mechanical performance, including dimensional stability. Parts made with AFT also Yannick Willemin, 9T Labs’ director, business development reveals how the company’s novel Additive Fusion Technology design & manufacturing standard is being used to make lighter, stronger, and cost competitive aircraft interior parts that produce zero waste. E A NEW INDUSTRY STANDARD Idealised continuous fibre preform reshaping by compression moulding process (below)
www.aero-mag.com Aerospace Manufacturing September 2023 13 offer a low buy-to-fly ratio along with excellent corrosion resistance. The overhead bin pin bracket is small, but numerous pieces are found throughout the cabin of an aircraft and are traditionally made of aluminium. Because this part has already been benchmarked with composite materials and the geometry of the small bracket is complex, 9T Labs chose this piece as a proof-of-concept to test and showcase AFT’s advanced capabilities. The results speak for themselves. The AFT-produced bin pin bracket costs 50% less and weighs nearly half of the machined aluminium counterpart. The thermoplastic discontinuous fibre bulk moulding compound (BMC) platelets and continuous fibre preforms used in the AFT process for the bracket represent a more sustainable material approach compared to aluminium. The BMC platelets, representing 80% of the final part volume, can be sourced from waste. Furthermore, the AFT-produced parts show higher strength, lower variation, and longer lifetime than aluminium. Data presented at the 2023 Society for the Advancement of Material and Process Engineering (SAMPE) Conference in Seattle detailed the real, demonstrable benefits of AFT to produce the bracket, which was originally made from a plateletbased material system. When using a hybrid material system with AFT to reinforce the brackets with about 20% by weight of continuous fibre printed preforms and platelets, measurable improvements were evident in mechanical performance of approximately 99.6% in the load at the onset of damage. In addition, the load at ultimate failure increased by 25.2%, and the coefficient of variance of the load at the onset of failure and at ultimate failure decreased by 46% and 14.8%, respectively. Reinforcing the pin bracket with continuous fibre preforms not only enhanced the strength characteristics but also decreased the variability in strength characteristic. Conclusion and outlook The overhead bin pin bracket is one small piece on a very large aircraft, but all together, small pieces add up and have a measurable impact on critical metrics like cost, weight and performance. Numerous reports have noted that even minor reductions in weight can have large impacts. For example, The Los Angeles Times reported that when United Airlines switched to a lighter paper for their in-flight magazine in 2018, it made the aircraft 11lbs lighter which meant 170,000 fewer gallons of fuel annually, resulting in savings of nearly $300,000. 9T Labs’ AFT platform is a game-changer in the aerospace manufacturing industry by offering the opportunity to create strong, light and less expensive parts that both deliver on performance and offer a more sustainable path forward vs. traditional materials. This is particularly true as it relates to the many geometrically complex and small parts that are critical to an aircraft’s overall performance, and it also holds true for larger parts, such as seat structures, as well. This is a versatile technology whose applications have only just begun to scratch the surface of what is possible. The company’s approach has been validated by life-cycle assessment (LCA); not only can it improve the environmental footprint by avoiding scrap and embracing recycling, but it has the potential to replace heavy metal parts on aircraft, which makes aircraft lighter, thereby requiring less fuel to fly. Traditional methods of manufacturing small size composite aerospace mechanical components have been hamstrung by high fabrication costs, which is why 80% of those parts are still made with metal. Additive Fusion Technology is future-oriented and solves the issue of higher fabrication cost while delivering highly effective and more sustainable solutions that stand to greatly benefit aerospace parts manufacturing. www.9tlabs.com Hybrid approach to combine multiple fibre architectures into a single moulded part (right) Mechanical performance with BMC vs. hybrid BMC (below right) Overhead bin pin brackets can be found throughout the cabin of an aircraft (below)
14 October 2013 www.aeromag.com ADVANCED MATERIALS: COMPOSITES September 2023 Aerospace Manufacturing www.aero-mag.com he aerospace sector was an early adopter of composite materials. The strength, weight, and corrosion resistance properties they offer were soon recognised by aircraft builders as providing substantial advancements towards more fuel efficient, comfortable and long-lived aircraft. Furthermore, over the years faster, more accurate, and repeatable production methods have been introduced which have greatly aided the adoption of composites across the industry. However, up until recently examples such as carbon fibre, have largely been confined to structural – and when it comes to engines – less critical aspects of aircraft. One company that has progressed composites being used more widely in the aircraft material mix through its manufacturing advances is Matrix Composites. Now part of ITT – a large industrial corporation that also includes: ITT Aerospace Controls (actuators, switches, fluid control devices and environmental control systems); Cannon (electrical connectors including aerospace applications) and Enidine (shock absorption and vibration isolation solutions), Matrix has been pioneering composite production techniques, particularly resin transfer moulding (RTM), infusion processes and trapped rubber moulding, for aerospace, defence, and space-related applications since its inception in 1993. Both Nadcap ISO9001:2015 and AS9100D certified, Matrix is also recognised as a Lockheed Martin STAR level supplier, the highest rating available, and supplies components for many of the most established global aero engine OEMs, airframers and composite part customers. A distinct production technology it has pioneered is Hot Isostatic Resin Pressure Moulding (HIRPM), an ultraprecise closed mould, out of autoclave process, developed specifically for manufacturing parts with critical edges and control surfaces. HIRPM is a highly accurate and repeatable process that provides faster production, superior laminated parts within 0.003” (0.0762mm) tolerances, a void content of less than 0.5%, that requires less post-process machining, significantly reducing production costs. “ITT acquired Matrix in 2019,” states William Zmyndak, vice-president and general manager, ITT Aerospace Control Technologies. “Its speciality is the design and manufacture of high temperature resin, RTM near net shape engine components, such as fan blade spacers and stators, but we also supply airframe makers and space industry customers. It adds another dimension to ITT’s aerospace business, supplying major engine builders and defence contractors and keeps us at the cutting edge of the development of composite parts.” Resin revolutions Matrix has experience in nearly every combination of fibre and resin including Epoxies, Bismaleimides (BMI) Cyanate Esters and Polyimides. Fibres include carbon, E and S glass fabrics and aramids. With the constant demand for ever lighter engine structures demanded by OEMs, Zmyndak is notably optimistic about the potential that Polyimide resins offer for hotter applications in aero engines. “Polyimides present a great opportunity for the wider use of composites in aircraft power sources,” he notes. “Heat has traditionally been the biggest factor to deal with when designing and making aero engine With its broad range of composite manufacturing services, Florida-based Matrix Composites has been pioneering the production of aerospace composite parts for three decades, and looks well primed to progress the next set of advances. Ed Hill finds out more. T INGENUITY IN THE MATERIAL A monocoque engine structure component made from BMI/carbon fabric using RTM (above) Mix parts, and up until now we have relied on metals and metal alloys to handle the higher temperatures, but of course this comes with weight disadvantages. As we have explored and developed the RTM process, composites, and resin systems, we are seeing their heat resistance properties increasing. There are now resin systems that can deal with temperatures of up to 300˚C and even higher. “These increased heat resistant resin systems will allow us to use them in more austere environments within the engine and for other high temperature Scan here for more Matrix articles
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www.aero-mag.com Aerospace Manufacturing September 2023 17 ADVANCED MATERIALS: COMPOSITES applications that we would not have been able to develop composite products for previously.” Zmyndak, a former director at Pratt & Whitney, believes much of the development in this area will be for military aero-engine applications and components as greener and more sustainable options for military aircraft become more predominant. “Sustainable solutions for military aircraft are not discussed as much as those for commercial aviation, but they are increasingly important,” he states. “In my experience with many different manufacturing processes for these applications, as resin temperature capabilities increase, composites will increasingly be found further and further in the heart of aero-engines. Processes such as HIRPM provide the ability to produce near net shapes in some highly complex forms and tolerances. “However, as we start to develop these higher temperature resin systems, the process science will be just as important as the material science. We must evaluate their flow properties, see how they perform in moulds, explore how the processes are developed and determine if that intellectual property can be extended to a wider range of parts.” Undoubtedly, if the next (6th) generation of fighter aircraft are to meet the performance targets demanded by armed forces, composites will play a substantial part. Already several programmes, such as BAE Systems’ Team Tempest, are researching advanced composite materials to produce lightweight power, dense systems able to operate at high temperatures. Rising rates In the meantime, Matrix is concentrating on keeping pace with the increased demand for components, particularly ramp-up rates after the Covid pandemic. But, like many highend manufacturing businesses, finding qualified staff is perhaps the biggest challenge. “OEMs are looking for ways to further leverage RTM technology, so in terms of the supply chain, demand is rising across the board. In that regard it is a good specialism to be involved in. However, to continue to grow we require people with technical talent that are familiar with composite materials and processes as we develop increasingly intricate components to meet the needs of the end user.” And the company is also investing in new technology in order to increase both capability and capacity. “We have just installed a new RTM press on the shopfloor that will give us the capability to do larger parts,” Zmyndak concludes. “We have also been adding to our 5-axis machining capacity and introduced software and on machine probing enabling us to make parts to much tighter tolerances. We aim to get to a point where we are both technology and manufacturing ready to make the more complex parts that will be demanded by the customer.” https://matrixcomp.com Precision wing tip element made with BMI/carbon fabric using Matrix Composites’ HiRPM process (above) Aircraft wing component made from BMI/carbon fabric using RTM (left) Matrix routinely applies the latest technologies to fabricate complex geometries (below left) William Zmyndak, vice-president and general manager ITT Aerospace Control Technologies (below)
18 October 2013 www.aeromag.com ADVANCED MATERIALS: MACHINING TECHNIQUES September 2023 Aerospace Manufacturing www.aero-mag.com s part of its push to offer the best possible levels of service to its customers, XYZ Machine Tools holds nearly £2 million worth of stock at its head office in Burlescombe, which equates to around 20,000 different parts in 18,000ft2 of storage on three levels. 70% of the stock is for the current machine range and the remainder are legacy parts for previous machine models including those which are 30plus years old, enabling the company to still supply the parts required to keep these older machines productive. The demands for the stores department come from several sources. The service department requests parts which are shipped directly to the customer for the service engineer to fit or replenish requests are issued to maintain stock levels for common parts in the 17 engineers’ vans. In fact, each van is considered as a stock location. Parts are also required for machine building. At Burlescombe, each machine is assembled, and individual customer options added before undergoing running, quality and health and safety assessments. BOM lists for each machine are pre-picked in the stores to ensure machines can be delivered on time. Finally, customers can order parts for self-fitting. Orders come from around the globe, so the shipping requirements can be complex to be able to fulfil these demands quickly and efficiently. The stores aim to ship parts for next day delivery when ordered before 3pm using a range of transport networks with the objective of keeping the machine running and offering a 1st class service. XYZ’s new spares website is now live. Within the site, it is easy to find products, with searches possible by machine type and model and part number. XYZ’s telephone support can, in any case, help customers identify the part they need. Again, parts are dispatched for next day delivery including for international orders. Within the stores, stock levels are maintained by the company’s MRP system backed up by physical stock checks to ensure accuracy and inject common sense into stock levels. A positive reaction As well as maintaining the smooth running of parts leaving the stores, deliveries of goods from local suppliers and the regular shipments from overseas need to be identified and quality and quantity checked when they arrive and again when they are issued from the stores, keeping track with incident reports where parts are not compliant. Barry Stanford, stores operative states: “Being reactive is key. Our aim is to find a solution to a problem first and then learn how it can be avoided in the future and, for that, our local parts knowledge is invaluable.” As part of increasing sustainability, the stores reuse clean packaging materials and Euro Pallets while others go through the company’s woodchipper to be used in the biomass XYZ Machine Tools keeps 20,000 different spare parts on the shelf to offer first class customer support. A SUPPLY AND DEMAND XYZ holds nearly £2 million worth of stock at its head office (above ) boiler. Previously, around 100 tons of wood each year went to landfill and the costs for this plus the heating costs amounted to over £70,000. With the biomass system the payback is less than two years, so it was an easy decision to invest. Furthermore, XYZ has also invested in solar panels, installing 112 capable of producing 46kWh which, connected to inverters, powers the factory during the day and has the option of exporting up to 23kWh back to the grid. EV charging points have also been installed at its Burlescombe, Nuneaton and Huddersfield showrooms. Nigel Atherton, managing director says: “We make a considerable investment in parts to make sure we can achieve the top-class service standards we set ourselves. As part of our operation, we are also conscious of our responsibility to the environment and sustainable working practices. We have made changes to mitigate our carbon footprint which make both economic and environmental sense.” www.xyzmachinetools.com Scan here for more XYZ articles
5-AXIS UNIVERSAL MACHINING CENTERS For the highest accuracy, dynamics & process reliability! www.grobgroup.com WANT TO KNOW MORE? CONTACT US AND VISIT OUR WEBSITE! GROB_Anzeige_Aerospace_magazine_UK_210x146mm.indd 1 22.05.2023 08:16:06 Increase brand exposure and generate leads! Promote your expertise and capabilities in association with key aerospace supply chain editorial. GDPR Compliant www.aero-mag.com Contact our sales representatives to discuss your marketing requirements David McCauley M: +44 (0)7557 308369 E: dmc@aero-mag.com Andy Morley M: +44 (0)7788 583432 T: +44 (0)1634 830566 E: amorley@aero-mag.com Editorial Programme July September October November January 24 Interiors Tooling Machining techniques Test & measurement Additive manufacturing Quality & inspection Assembly techniques Surface finishing MRO DSEI* EMO Hannover Aeromart Singapore Airshow 30 June 4 August 22 September 27 October Machining techniques Automation 15 December Advanced Engineering* Electric aircraft Helicopters Military aircraft Civil aircraft Avionics Landing gear Wings Engines Materials supply Supply chain accreditations Procurement Reshoring Supply chain partnerships Product lifecycle management (PLM) Production control software Simulation & visualisation CAD/CAM Industry 4.0 Sho FEBRU • Sou Elec ww APRIL • JEC ww JUNE • Sub ww • Ma Birm ww • TCT http • Airc ww • Par ww SEPTE • DSE ww • EM http NOVE • Adv Birm ww FEBRU • Sing ww llllllllllllllllllllllllllllll Show date Space programmes Aero Media Pack 2023.qxp_Layout 1 04/10/2022 14:54 Page 5 July September October November January 24 Interiors Tooling Machining techniques Test & measurement Additive manufacturing Quality & inspection Assembly techniques Surface finishing MRO DSEI* EMO Hannover Aeromart Singapore Airshow 30 June 4 August 22 September 27 October Machining techniques Automation 15 December Advanced Engineering* Electric aircraft Helicopters Military aircraft Civil aircraft Avionics Landing gear Wings Engines Materials supply Supply chain accreditations Procurement Reshoring Supply chain partnerships Product lifecycle management (PLM) Production control software Simulation & visualisation CAD/CAM Industry 4.0 Sho FEBRU • Sou Elec ww APRIL • JEC ww JUNE • Sub ww • Man Birm ww • TCT http • Airc ww • Par ww SEPTE • DSE ww • EM NOVE • Adv Birm ww FEBRU • Sin ww llllllllllllllllllllllllllllll Show dat Space programmes Aero Media Pack 2023.qxp_Layout 1 04/10/2022 14:54 Page 5
20 October 2013 www.aeromag.com September 2023 Aerospace Manufacturing www.aero-mag.com SUPPLY CHAIN: DIGITALISATION he aerospace and defence industry saw tremendous gains in 2022, with billions of dollars being invested across the industry. This growth was driven by several factors, including the need for new commercial aircraft, an increase in new defence programmes, the growth of urban air mobility, a rise of commercial space ventures, and an industry-wide push toward sustainability. A&D companies, however, are discovering it is much easier to find money than it is to spend it because delivering new products requires two things that are in short supply: skilled labour to design and assemble the products, and the parts to build them. Overcoming these challenges is more complicated than simply recruiting more people, building more parts or even just working harder with the tools already available. To succeed, the A&D industry must fully embrace digital transformation. While many companies have adopted digital technologies, most are just using them as individual tools, which largely remain separate islands of unique sets of data. Data is moved between these islands in Excel-powered rowboats, paddled by engineers. There is untapped opportunity for innovation and transformation that goes beyond the adoption of individual tools. A holistic approach to engineering would connect the islands and streamline the flow of data, enabling companies to Todd Tuthill, vice-president of aerospace & defence, Siemens Digital Industries Software looks at how best to solve A&D’s staffing and supply chain issues with digital transformation. T A CHANGE FOR THE BETTER Embracing digitalisation can transform challenges into opportunities (above)
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