Producing composite parts for high-qualified products such as solar arrays, fuselages and rotor blades is, due to the delicacy of the material, mainly done by hand. As a result, composites are an expensive product. That is why we translate the fundamental assets of Industry 4.0 to our high-qualified composite manufacturing processes. We believe composites can be affordable for high-end markets such as Aeronautics, Space, and Marine, and Airborne has the capabilities to industrialise a broad range of composites manufacturing processes through the means of automation and digitalisation.
20 years of composites know-how
Do you know deep sea is even more challenging than deep space? With a revolutionary idea for the production of extremely affordable composite pipes for the Oil & Gas market, Airborne already showed some 20 years ago it is able to create solutions and think beyond given restrictions of qualification rules and regulations. Our challenge was to develop industrialised manufacturing lines for thermoplastic composite pipes, used at 3000 meter depth. And so we did: nowadays Airborne Oil & Gas is the world’s first and leading company in this field. With this experience Airborne knows automating and digitalisating composites manufacturing processes is the only path to follow.
High-end composite parts and production lines
Airborne produces high-end thermoset and thermoplastic composite parts and develops fully automated production lines. We can either produce these parts in-house through advanced manufacturing or we develop industrialisation packages which we implement at manufacturers of choice.
As a result, our clients can rely on high flexibility, low costs and a reduction of lead times.
How do we automate composites production?
Transfer traditional composite manufacturing to Airborne
Airborne’s proposition is the following: You, our client, partner with Airborne in order to benefit from our automation development. A suitable programme is selected. Airborne transfers your composite production to the Airborne facility.
Airborne automates the process
Initially we will use traditional, manual methods for composite production. During this phase, our engineers closely analyse the manufacturing process for composites in order to identify the steps which are critical to quality. Based upon this knowledge, automated manufacturing lines will be developed and qualified.
Select future manufacturing location
After successful qualification, the initial production will be taken over by the automated production line. After an agreed period, the choice is yours:
- Airborne continues to manufacture composite parts in our own facility
- Airborne installs a production line for composites in your facility
- Airborne installs a production line for composites at a supplier of your choice
How do we digitalise composites production?
Automation means data. Data which we can use for digitalisation in order to improve our production processes. With our partner Siemens, Airborne has established a Digital Factory Composites Field Lab. Within this development center, we are working on the ‘Digital Twin’: a digital version of both the product and the composites production process. The KUKA robots are equipped with special sensors and actuators, providing all data necessary.
We simulate the total manufacturing process, accurately measure and record each action, and follow all editing steps and flaws. This allows us to produce a composite part automatically, without the intensive testing of a non-destructive prototype. Conducting all the production data will be sufficient for all qualifications.
How does it work?
Our concept:
-
Modular
-
Off-the-shelf robots
-
Interchangeable end-effectors
-
Software integration
Contact me
Marcus Kremers – CTO Airborne
For more information about our products and services, please contact me:
© All rights reserved