Global Aeronautics and Space Manufacturer
Supporting the ‘Wing of Tomorrow’ Programme
Background
Our client is the largest aeronautics and space company in Europe, and a worldwide leader at the forefront of the aviation industry. With a pioneering spirit that has redefined the aerospace industry, our client strives to continually push the boundaries on what is possible to safeguard the world for future generations.
The ‘Wing of the Tomorrow’ programme is a transnational research and technology programme with a development centre in Filton, UK. Its aim is to accelerate the design, construction and testing of wings for next generation aircraft, using the latest technology and world-leading demonstrators to further improve performance.
GKN, Spirit and the National Composites Centre approached us to join as partners in the programme to help solve the challenge.
Challenge
Our client were manufacturing aircraft wings using pre-preg materials in autoclaves. Experiencing, increased industry demand for aircraft, the pre-preg process was proving too expensive to scale up, in response to rapidly growing order books
The Wing of Tomorrow Programme invested in R&D to explore alternative methods of manufacturing, including infusion and RTM to answer the following questions:
- Can we prove infusion and RTM are a viable, cost-effective alternative to pre-preg wing manufacture?
- Can we match the structural standards of pre-preg and meet safety requirements?
- Can we reduce wastage and energy consumption involved in pre-preg and post production, making the process more sustainable?
- Can the process handle both single and dual component resins?
Solution
The physical part design and tooling had been specified by the tier-one partners. Working closely with them, our CI experts:
- Reviewed the part and tooling design, analysing the structural and production requirements needed.
- Scoped an automated Infusion and RTM process to deliver to the R&D specification.
- Specified a bespoke CIJECT LSRI to meet the exacting demands of aerospace processing.
- Specified ancillary pressure sensors, catch pots, a manifold system, injection and venting to automate the process.
- Specified a data system to monitor and optimise the automated process, and provide research data to the R&D team.
- Installed the system, and supported the factory and site adoption process.
- Provided ongoing operator training, and preventative maintenance.
Results
- So far, the Wing of the Tomorrow R&D programme has successfully completed three wing test structures, proving the RTM process is a viable alternative to pre-preg production.
- The R&D findings are just a stepping stone in the overall project. There is still work to be done before the wings are in full mainstream production.
- The next project is the ‘Wing Accelerator Project’ which will aim to prove that the process can scale to achieve a production rate of 60 wings per month.
