Airborne is passionate about increasing the use of composites, reducing transformation costs and enabling rate manufacture. However many companies need support in understanding the many interdependencies inherent in designing and manufacturing a composites product. We understand every phase of industrialisation and can advise on all of the key aspects that define product cost and performance. We are your partners, from start to end, and are committed to deliver you the full industrialised manufacturing solution. We can do that by implementing the automated manufacturing systems on your shop floor, or by supplying you the products made by us with the industrialised manufacturing process.

Our 25+ years legacy in advanced composites design and manufacturing, makes us experts in supporting you with your product development challenges, whatever market you are in, or whatever stage of development you are at:

• You may be considering whether to replace a metallic structure with a composite one and wish to understand functional feasibility, as well as cost estimates for parts and tooling for different production rate/volume scenarios.

• You know that a component should use composites to improve performance, but may be unsure of the right materials and process and need to understand the trade-offs.

• You have designed the product, but need to anticipate higher rate manufacture, and would like some advice on how to design for automation/rate.

• You know automation is needed, but may not be familiar enough with the economics and business cases pertaining to the different processes to make a decision.

Our experienced engineers have capability across design, processing, manufacturing, automation and digitalisation.

STEP 1: Evaluate

In the early stages of product development you need to evaluate the fundamental questions. Our feasibility and engineering studies are structured to meet clear deliverables, with transparent logic and conclusions.

In detailed design, there are many trade-offs to be considered through materials; process; tooling etc. Airborne provides clear summaries and calculations that make decision making easy.

STEP 2: Automate

Later, depending on demand, production rate and cost challenges, automation may be needed. We provide the operational analysis to describe automation options, their effect on production economics, and the business case for investment.

Our solutions will include our own technology where available, or offer support with integrating third party options where more appropriate.

• Feasibility & cost estimates of composite structures

• Product Design and Structural Engineering

• Independent material advice

• Processing/manufacturing options

• Tooling options

• Trade-off studies

• Business case development including payback time and ROI

• Design for Automation

• Automation and digitalisation solutions

• Implementation of automation and digitalisation

• Turn-key delivery

Automated Kitting

Automated ply picking and sorting to optimise nest efficiency and ensure quality with low labour cost.

Automated Laminating

Automated deposition of prepreg for net shape preforms.

Automated Preforming

Assembly of 2D and 3D preforms to achieve TAKT times at automotive rates.

Design & Manufacturing

Craving manufatcuring expertise, design capability or products for Space? Airborne also offers design and manufacturing services.

Automated Systems

Want to get started with automation? Airborne offers various automated solutions and techniques to help you move forward.

Digital Solutions

Want to use composites without first becoming an expert? Our smart digital and software solutions make composites and automation available to anyone.