In modern aircraft production, precision is everything. Every hole and every fixing point must be precisely positioned to ensure safety and quality. As part of the DiCADeMA project (Digital Cabin Architectures and Design for Manufacturing) led by the German Aerospace Centre (DLR), a novel, fully digitally networked process has been developed.

Through intelligent automation, this approach elevates aircraft cabin manufacturing to a new level. A key component in this process is an Ensenso 3D camera from IDS Imaging Development Systems, which ensures highly precise detection and alignment of drilling positions.

Digital process chain from design to production

The aim of the project is to establish a continuous digital thread from design to production. Changes to the cabin design, such as seat spacing and the associated new position of the luggage compartments, are recorded directly in the digital design data and automatically transferred to production planning. Simulations allow these variants to be validated before any physical component is manufactured. Once digital validation is complete, production can begin immediately.

To make this digital process tangible, an automated system for marking drilling positions was developed on a mock-up of an aircraft frame structure. Several networked systems work together in this setup: An autonomous mobile robot (AMR) approaches the frame and positions itself near the target area. Mounted on the AMR is a lightweight robot that moves the marking unit, including the 3D camera, into the acquisition position. At this point, the Ensenso camera takes over the fine alignment. An integrated Manufacturing Execution System (MES) controls all sub-processes.

The role of the 3D camera

The camera used, an Ensenso N36, captures the environment as a three-dimensional point cloud and matches it against the CAD data of the aircraft frame. In this way, even the smallest deviations between the target model and the actual geometry can be detected. The system uses this data to calculate precise correction values, which are transmitted to the higher-level MES.

Communication takes place via a standardised OPC UA interface, ensuring reliable and secure data exchange between the camera, the robot and the control system. The MES translates the acquired data into concrete control commands for the robot, which then performs the marking of the drilling position.

The autonomous robot achieves a positioning accuracy of around five millimetres. This allows the camera to reach the acquisition position without risk of collision.

The Ensenso camera becomes a key link between digital design and real-world manufacturing: It recognises local geometries, in this case several rivets and the surface on which they are set and compares the captured point clouds with the reference data from the CAD. This comparison is made possible, among other things, by hand–eye calibration and an iterative minimisation process. The result is a transformation matrix that precisely describes the correction required for the drilling position. By applying this correction value, the drilling position can be set precisely.

An operator follows the vehicle and drills the hole immediately afterwards at the marked spot. This process is repeated for each installation point, while robots and humans can work safely in close proximity to one another.

For this application in aircraft manufacturing, a compact camera with a very short working distance is required in order to keep the path from the acquisition position to the drilling position as short as possible. This helps to maintain high accuracy and avoids excessive robot movements. The Ensenso N36 meets these requirements. The Ensenso N series has been specially developed for use in demanding environmental conditions.

Thanks to its compact design, the camera can be installed in a space-saving manner, either in a fixed position or mounted on a robot arm. This makes it equally suitable for 3D capture of both moving and stationary objects. The integrated projector ensures high-contrast texture even under challenging lighting conditions: It projects additional structures onto the object surface using a pattern mask with a random dot pattern, thereby supplementing missing or weak features. All cameras are pre-calibrated at the factory and can therefore be put into operation quickly and easily.

Benefits for manufacturing

The digital process offers the DLR several advantages. Camera-based alignment significantly increases precision and repeatability. At the same time, continuous data acquisition enables complete documentation and traceability of all process steps. Assembly personnel are relieved, as the robot takes over the time-consuming task of position determination, allowing skilled workers to focus on the actual assembly operation. In addition, production times are significantly reduced, as manual measurements or readjustments are no longer necessary.

The demonstration on the mock-up clearly illustrates the potential that lies in combining the digital process chain, robotics and 3D image processing. In further project steps, the accuracy of the system and the performance of the evaluation algorithms will be examined in greater detail. This will involve not only the camera itself, but also the optimisation of the mathematical methods used to align nominal and actual point clouds.

What is currently being tested in aircraft manufacturing may also be applied in other industries in the future. The system impressively demonstrates how optical sensor technology and intelligent software are paving the way for a new era in manufacturing: networked, efficient and precisely on target.

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Composite aero-structures, primarily based on carbon fibre and epoxy resins, are essential in modern aerospace to reduce weight, increase strength, and improve fuel efficiency. Their use in fuselages, wings and stabilisers provides longer service life and greater corrosion resistance compared to conventional metals.

The production and machining of these large components require extremely tight tolerances. Although standard industrial robots offer flexibility, they typically lack the rigidity and precision needed to meet such demanding requirements.

At the upcoming edition of the International Machine Tool Biennial (BIEMH), IDEKO will present the results of the work carried out in an intelligent robotic cell integrating drilling, deburring and inspection operations on a composite aero-structure representative of an aircraft wing.

The demonstrator will highlight the full set of technologies, methodologies, and tools specifically developed by the centre for manufacturing these components, significantly reducing robot positioning errors during machining tasks.

Combining advanced capabilities

In the design and development of these high-precision robotic cells, IDEKO combines several advanced technological capabilities, positioning itself as a leading player in applied R&D&I for the aerospace industry.

On the one hand, the centre’s strong expertise in photogrammetric measurement technologies has led to the development of an innovative computer vision system capable of continuously tracking the robot end-effector across large working volumes and correcting its position in real time. The solution integrates predictive models to optimize metrological performance and enables automatic camera repositioning based on the machining trajectory.

On the other hand, IDEKO has enabled the robot to perform automatic component referencing, generate and adapt movements to real parts once clamped in fixtures, and automatically adjust machining operations to the measured geometry. These advances drastically reduce the need for manual adjustments and improve process repeatability.

In parallel, IDEKO has integrated technologies aimed at achieving more efficient, intelligent, safe, and sustainable machining. These solutions help prevent common defects in composite materials, such as delamination. Additionally, in the case of carbon fibre – widely used in aero-structures – the centre has developed and validated systems to contain and extract the toxic dust generated during machining operations.

The incorporation of advanced sensing technologies allows potential issues, such as vibrations, to be identified in real time, enabling timely intervention in the process.

These digitalization and advanced analytics capabilities contribute to improving surface quality, extending tool life, and enhancing workplace safety.

To address the structural limitations typically associated with commercial robots, the centre has also developed extensive expertise in defining and validating robotic cell architecture design. This know-how is complemented by strong capabilities in the conceptual design and commissioning of advanced fixtures for clamping and referencing large components, specifically tailored to composite aero-structures.

In this work, IDEKO considers critical aspects such as robot and machining head accessibility to all functional areas of the component; control of deformations induced by gravity and the clamping system; compatibility with automatic referencing and digitalisation systems; and positioning repeatability in machining operations.

This comprehensive portfolio of technologies aimed at optimising industrial robotics performance in aerospace production will be showcased at IDEKO’s stand in Hall 1 at the Bilbao Exhibition Centre (BEC) from 2-6 March, 2026.

To address this situation, the technology centre IDEKO has contributed to the development of a new generation of flexible, sensorised and connected robotic cells within the framework of the ROBOCOMP project. Led by the DANOBAT cooperative, this initiative aims to transform the manufacturing processes of aeronautical components.

“The new solutions are designed to replace traditional systems and automate critical machining operations on carbon fibre parts, such as milling, drilling and trimming, in order to boost efficiency and reduce energy consumption,” explains the centre’s researcher, Asier Barrios.

This technological transition responds to specific operational limitations of current machinery. While large traditional equipment usually machines parts in a horizontal position, restricting access to many components with complex geometries, ROBOCOMP’s proposal introduces the ability to work on parts placed vertically.

This feature also facilitates production scalability, allowing plants to adapt quickly to new manufacturing requirements.

Precision and monitoring

The contribution of the technology centre, a member of the Basque Research and Technology Alliance (BRTA), has been essential in providing intelligence to these new solutions. Specifically, IDEKO’s scientific work has focused on increasing robot precision through improvements in mechatronics and system calibration, a critical factor in meeting the strict requirements of the aerospace sector.

In addition, the centre has equipped these cells with the intelligence required to operate autonomously. Through artificial vision systems and sensors, the robots are able to see and analyse the status of the manufacturing process as it takes place. This digitalisation allows the process to be monitored in real time, instantly identifying possible errors or deviations to ensure the quality of the part.

Sustainability has also been addressed within the initiative, through the implementation of technologies that optimise the machining of composite materials to ensure more efficient use of energy and resources.

Transfer to other sectors

The success of the initiative has been supported by a solid industrial consortium covering the entire value chain. Alongside the leadership of DANOBAT and the scientific knowledge of IDEKO, the project has benefited from the participation of Airbus, which has contributed the end user’s vision and requirements; Robotnik, a European leader in mobile robotics; and Industrial Olmar, a company dedicated to the manufacture of autoclaves and pressure equipment.

This collaboration has enabled the development of technologies that position the Basque and Spanish industrial fabric at the forefront of advanced manufacturing, with a clear drive towards other markets.

The technologies developed at ROBOCOMP will be transferable to other machining-intensive sectors, such as automotive, energy and capital goods, thereby strengthening the competitiveness of small and medium-sized enterprises and opening up new business opportunities in the field of advanced services and smart maintenance.

The project has been funded by the Centre for the Development of Industrial Technology (CDTI) through the Aeronautical Technology Programme (PTA), a grant framed within the Recovery, Transformation and Resilience Plan of the Government of Spain.

A good example of such useful GSE is automated aircraft-cleaning robots. These modern cleaning systems can optimise productivity and protect workers from significant risks associated with manual cleaning operations. Veronika Andrianovaite, CCO of Nordic Dino Robotics, explains how robotic cleaning systems can transform daily airline operations by prioritising worker safety and setting new industry standards.

Although manually cleaning aircraft exteriors is considered standard in aviation, it presents several risks. Exposure to hazardous chemicals, physical strain, and working at dangerous heights – all of these factors pose potential dangers to personnel. As well, the process of manually cleaning an aircraft involves repetitive motions, lifting heavy equipment, frequent bending and stretching. Over time this can lead to fatigue and strain among maintenance workers. To address this issue, ground handling companies could adopt robotic cleaning systems like Nordic Dino, which help reduce human labour.

“These advanced machines are designed to handle the most demanding aspects of cleaning, reaching high and low surfaces effortlessly. The shift toward robotic aircraft-cleaning systems significantly reduces risks for those working in the industry and also enhances efficiency, thereby reducing ground handling costs,” says Veronika Andrianovaite.

One more issue is the use of powerful cleaning agents – chemicals that help remove dirt, grime, and environmental contaminants that accumulate on the aeroplane exterior. But when workers are frequently exposed to them, these chemicals can pose serious health risks. Veronika Andrianovaite warns that direct contact with harsh substances may lead to respiratory problems, skin irritation, and other long-term health concerns.

“Robotic systems provide a safer alternative by automating the application of cleaning agents. It ensures precise and controlled distribution of the chemicals and minimises human interaction with potentially harmful substances. Moreover, those modern systems help to optimise the use of cleaning materials and, at the same, time reduce waste, environmental impact, and water consumption,” comments the CCO of Nordic Dino Robotics.

According to the International Air Transport Association (IATA), the most frequently reported injuries among ground handling staff include slips, trips, falls, being struck by objects, and injuries related to lifting, carrying, pushing, or pulling. Falls from heights, though less frequent, are among the most severe.

Working at elevated heights is a serious threat that workers face while cleaning the aircraft exterior manually. To clean the upper surfaces of an aircraft, the personnel often use scaffolding, lifts, or platforms, bringing the risk of falls and severe injuries. Furthermore, specific weather conditions, such as strong winds or rain, can increase the danger of harming yourself.

“Advanced aircraft cleaning robots are equipped to navigate and clean elevated areas autonomously or by using remote operation. This allows workers to remain safely on the ground. These days, modern robots like Nordic Dino can prevent workplace accidents and enhance safety standards,” notes Andrianovaite.

As the aviation industry continues to evolve, robotic cleaning systems are proving to be an invaluable asset to ground handling operations. Automated systems help airlines maintain the pristine appearance and operational efficiency of aircraft. Alongside this, high-tech robots protect the health and enhances the safety of those who keep the aircraft in top condition.

“The system was required to have the capability to mask 14 component variants, while offering the functionality to add additional variants in the future,” explained Craig Hamilton, Business Development Manager at Astech Projects.

Part of Schauenburg International group of companies, Astech Projects is a supplier of robotics and automation solutions to the advanced manufacturing and regulated industries including pharmaceutical, medical device, consumer healthcare, chemical, aerospace and automotive. It builds systems from concept to completion on a custom basis, and can turn their hands to any application not currently available in the market.

“The main drivers behind the project were to accurately and repeatably mask the component,” said Baseley. “The final result dispenses to an accuracy of 100 microns, a great achievement. Astech Projects’ bespoke system offers the client a significant labour saving and increases throughput, with the client now channelling 60% of its components through the system.”

Fully automated system

Together the team came up with a fully automated system which incorporates a 3-axis cartesian robot and two 6-axis robots working in sync according to one robot program. It also includes a high-definition vision system, masking dispensing system and UV curing station.

On a batch-by-batch basis, the system can correctly identify and orientate 14 types of part against the preeflow eco-PEN450, which accurately dispenses the Dymax 717-R SpeedMask product.

The part is then taken to a curing chamber, where it is illuminated with high intensity UV. Once the process is complete, the component is returned to its original input location. The process repeats itself until the entire batch of components has been processed.

“Intertronics is an extremely knowledgeable company, providing Astech with vital coatings expertise. Intertronics was a great partner for this project and we look forward to working together in the future,” concluded Hamilton.

The ADUbot has been developed in conjunction with aerospace automation specialist Electroimpact and Luebbering, leading manufacturer of high precision fastening and drilling tools and technology. By automating the traditionally manual task of drilling thousands of holes in airframes – and using tools that have already been qualified – the ADUbot will assist aircraft manufacturers to rapidly achieve high levels of drilling autonomy, freeing up human employees to take on more value-added tasks.

“The record number of orders for aircraft over the next decade means that manufacturers and suppliers, across the whole supply chain, are having to streamline operations and cut cycle times while, at the same time, maintain the highest standards of quality and safety,” says Oliver Selby, Head of Sales at FANUC UK.

In a bid to help aircraft manufacturers increase production rates without impacting on quality, the FANUC/Electroimpact/Lueberring partnership identified drilling as a key application that would benefit from being automated.

“Traditionally, operators rely on a standard aerospace hand tool that uses a concentric collet locking interface to metallic drill templates or drill jigs that are attached to the wing. These drill tens of thousands of holes in aircraft every day – yet they are all operated by hand,” explains Robert Brownbill, Senior Mechanical Engineer for Deeside-based Electroimpact. “The operator must locate the end of the drill unit into the drill jig, then activate the locking collet to begin the process, drilling an incredibly high-tolerance hole into the structure. The collet is then unlocked, and the operator moves to the next hole.”

Accurate, fast and safe

By contrast, the ADUbot developed by FANUC, Electroimpact and Luebbering, sees a FANUC CRX-25iA cobot take over the manual aspects of this drilling process. As a collaborative robot, it is designed to operate safely with human personnel in close proximity. It can be quickly programmed for the task at hand and equally quickly be reprogrammed for the next job. It is mobile and can be moved easily from one location to another, making it especially suited for aircraft assembly operations.

Accuracy is also crucial – each hole has to be drilled to a very tight tolerance in terms of location and dimensions. “The use of FANUC’s Force Control routines allows us to utilise the existing manual drill jigs to locate ADUbot into the drill jig, and then we can command the ADU to drill the hole,” says Robert. “The ADUbot still requires some manual support in fixing the drill jig to the structure. However, once that’s done, ADUbot can be wheeled into place, the jig resync targets scanned, and the system left alone to complete the drilling processes. The major benefit to this process is that one operator can now operate many ADUbots, making it much more efficient.”

Overcoming validation hurdles

A particular challenge for any new process within the aerospace industry is that it often requires qualification before it can be used on a flying aircraft. The validation process can be lengthy, which can discourage the adoption of even the most innovative new ideas and processes. Return on investment (ROI) usually has to be high to overcome this hurdle. FANUC, Electroimpact and Luebbering have turned that situation on its head by offering a solution that can be deployed immediately, with low capital investment.

“The beauty of the ADUbot is that it uses tools that have already been validated,” says Oliver Selby. “As end-users won’t have to go through the validation process, we can save them months in getting up to speed on automation. It’s a very cost-effective solution with a fast ROI.”

Drilling may appear to be a straightforward process to automate, and in many ways, it is. However, achieving the precision required for aerospace tolerances presents significant challenges. The simplicity of using a pre-qualified tool makes this the perfect application for automation.

“When companies begin their automation journey, they often start with the more difficult-to-operate tasks,” states Robert. “But the more complex something is to operate manually, generally, the more expensive and more complicated it is to automate. The ADUbot is deliberately aimed at a task that is repetitive, routine and ultimately, easier and cheaper to automate. It’s the perfect entry-level system for companies that may be at the start of their automation journey, as well as those that are more familiar with robotics.”

Plugging the labour gap

Skills and staff shortages are squarely in the partners’ sights, too. “One of the biggest challenges we have heard from our customers is that they’re struggling to recruit the skilled workforce they need to increase their capacity. It’s therefore essential that manufacturers make the best possible use of their existing operators,” continues Robert. “Automating the ‘simpler’ jobs, such as drilling, frees up that skilled labour pool to carry out more complex tasks.”

This view is echoed by FANUC’s Oliver Selby: “The projected growth in the aerospace industry, with nearly 200 new aircraft to be delivered every month for the next 10 years, means that manufacturers across the supply chain have to work to shorten cycle times in every aspect of production. At the same time, the industry is facing skills shortages and a very tight supply of new recruits. The solution is automation – to get more robots carrying out more tasks, faster and reliably, helping human personnel to be more productive and focused where their skills and experience are most effective.”

Long-term collaboration

As a company that works with the world’s leading aircraft manufacturers in the USA, Europe and elsewhere, Electroimpact has enjoyed a long-running partnership with FANUC. The majority of its large-scale, complex and custom multi-axis machines are FANUC CNC controlled.

“We are delighted to announce the launch of this new solution, the latest fruits of FANUC’s long relationship with Electroimpact and Luebbering,” says Oliver. “The ADUbot will help suppliers and OEMs to cut cycle times and boost productivity, with a very low investment and rapid ROI. This is another step along the road to meeting rapidly rising demands for new aircraft in the global market.”

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An operator oversees drilling on an A320 fuselage in Hamburg, Germany – image copyright Hermann Jansen

In the face of unprecedented demand for new aircraft, robotics specialist FANUC is helping the aerospace industry to increase production efficiency and boost output. Over the past five years, FANUC has supported Airbus with its in-house robotics strategy, culminating in Airbus developing a robotic drilling system which employs a FANUC M-800iA/60 six-axis robot.

The system has improved drilling accuracy and increased productivity for Airbus, while freeing up human employees to work on more creative and value-added tasks.

The start of this year (Q1 2024) saw the global aircraft order backlog hit record-breaking heights, reaching 15,812. Automation and robotics are considered key levers to support this increasing demand. FANUC has long championed the use of its industrial robotic solutions as a way for aerospace manufacturers to boost production rates, streamline their operations and cut cycle times.

“Automation has become crucial in closing the gap on the backlog in aircraft orders as it significantly enhances production efficiency, reducing the time needed for manufacturing complex components,” says Oliver Selby, Head of Sales for FANUC UK. “Additionally, automation minimises human error and allows for more consistent quality control, ensuring faster turnaround times and enabling manufacturers to meet demand more effectively.”

Automating drilling tasks

Boasting advanced automation technology and an experienced team of robotics experts, FANUC was the ideal company to support Airbus in the development of its in-house robotics division. With its multiple drilling applications still largely completed manually, automating this process was a priority – but sourcing a robot that was robust enough to meet Airbus’ requirements initially proved a challenge.

“The specific solution that Airbus was looking for did not exist anywhere in the market,” explains Oliver. “The robot in question needed to be extremely rigid and stiff but also highly accurate, and with a minimum 60kg payload. We therefore worked together with Airbus to develop a prototype and refined this until it precisely matched their specifications for lower payload/small hole drilling.”

From prototype to production

This prototype has gone on to become the M-800iA/60 six-axis model, which is now part of FANUC’s standard industrial robot range. Also suitable for laser cutting, welding or other applications which require extremely high levels of accuracy, it offers outstanding precision without slowing down the production process.

Following rigorous testing and validation with FANUC, Airbus placed the first commercial order for the M800iA/60. The robot is now part of Airbus’ proprietary automated mobile drilling system. This system has now gone into production and represents the first of a new generation of robotic solutions for Airbus that have been custom designed by its in-house experts, with technical support provided by FANUC. Now on its way to being integrated into the A320 Family pre-assembly line, it adds value to Airbus’ manufacturing processes by reducing costs and stoppages, all while improving quality and saving time.

Reaping the rewards of robotics

Since the introduction of the M800iA/60 to the market, FANUC and Airbus have further developed the technology and implemented it into larger robots in the high accuracy/high stiffness range – 190kg and 270kg payload versions are now available, with a reach of 2m and 2.7m respectively. These additional FANUC robots could allow for further adoption in other applications within Airbus as they move to higher rate production to meet increasing global demand.

“There are numerous benefits to aerospace manufacturers of automating their drilling applications with the M800iA/60, including improved accuracy and repeatability, increased output, and better use of personnel for more value-added tasks,” states Oliver. “Longer term, the development of an in-house robotics division should also enhance the industry’s ability to attract high-level talent to technology-driven, innovative and future-ready companies.

“From FANUC’s perspective, working with Airbus has been an extremely positive and rewarding experience. Showcasing the benefits of automation and robotics to the aerospace industry is vital in helping the sector to reduce the current backlog. This project demonstrates how important it is to collaborate with a robotics partner that will provide the right experience, knowledge, training and technology to support companies to achieve their commercial aims. We hope this will be the first of many such collaborations between FANUC and Airbus to increase efficiency within their manufacturing applications.”

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FANUC’s automation demonstrations, in conjunction with their industry leading partners, will cover a variety of key applications essential for the aerospace sector such as dispensing, polishing, inspection, machining and drilling, helping manufacturers to meet increasing order levels by boosting productivity.

Futureproofing to increase output rates

The aerospace industry is booming. Commercial revenues are expected to grow 14% year-on-year over the next 10 years, while passenger traffic will grow by 3.6% annually up to 2044. Around 22,120 new aircraft will be delivered between 2024 and 2033 – this equates to nearly 200 a month, every month, for the next 10 years.

“While this is great news for the industry, it means that manufacturers will need to find ways to increase production rates,” says Oliver Selby, Head of Sales at FANUC UK. “Operations have to be more streamlined and cycle times must be cut, all while maintaining the highest standards of quality and safety.”

Flexible future of the factory floor

Flexibility in manufacturing will be another key element in the industry’s successful growth. To this end, the FANUC stand will feature the University of Nottingham’s world-class OMNIFACTORY project. A five-year, £3.8 million facility that employs advanced technology and methodology to make manufacturing more efficient and cost-effective, OMNIFACTORY is a bespoke test-bed floor which autonomously adapts to the next product’s environment and specifications.

The demonstrations around the project’s AGV show a combination of digital technologies, robotics and artificial intelligence including robotic surface preparation and dispensing. The aim of this proof-of-concept project is to inspire a new generation of smart, highly efficient factories, embedded in local supply chains.

The power of partnerships

A variety of automated systems from some of FANUC’s key partners – each employing FANUC robots at the heart of their technology – will also be on display at the event. One such example is an advanced metrology solution from Hexagon.

Showing how data can be used throughout the product lifecycle to accelerate aerospace innovation and efficient manufacturing, Hexagon’s Presto Robotic Metrology system dramatically cuts the time required to devise inspection routines, by reducing them to a single step. Built on leading scanning technology, this flexible, modular cell has been designed to effectively meet the evolving needs of modern manufacturing.

Meanwhile, an aerospace drilling cell developed by Electroimpact and featuring a FANUC CRX-25iA cobot, will demonstrate accessible and cost-effective pre-validated drilling functionality for the aerospace sector, offering improved reliability, repeatability and traceability compared to manual practices.

The growth of eVTOL

Finally, with the eVTOL sector being a key focus at this year’s event, FANUC will also showcase its ROBODRILL vertical machining centre, featuring a Nikken 5AX-201 tilting rotary table. This combined machining and turning cell enables difficult to hold components to be rapidly mounted and changed, even where space is limited.

“With a compact footprint, this is a perfect, cost-effective solution for small castings, using aerospace grade alloys, for products like eVTOL motor housings,” Oliver explains.

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Three FANUC M-2000iA/1700L six-axis units will be delivered to the University of Sheffield Advanced Manufacturing Research Centre (AMRC) for its new innovation facility in South Yorkshire. This is part of Project Compass (Composites at Speed and Scale), a larger £80m investment which includes an aerospace manufacturing R&D project delivered by a consortium of partners including Boeing, Loop Technology, Spirit AeroSystems and the AMRC. The Loop/AMRC deal also encompasses two further FANUC M-2000iA robots: a 1200L and a 900L model.

As part of a separate project, another 1700L model, along with an additional 900L unit, have been ordered by Loop Technology to form part of a high-rate composite preforming cell for a North American aerospace client. This brings the total number of FANUC M-2000iA six-axis robots commissioned by Loop Technology for this latest order to seven.

Decarbonising the aerospace sector

The aerospace manufacturing sector is booming, with 3,850 aircraft orders being placed in 2023 – a global record, according to ADS, the trade association for the aerospace, defence, security and space sectors. However, there is also currently a global aircraft backlog of 15,753, which is the largest on record. Increasing the level of automation in aerospace manufacturing is one of the main ways to increase productivity and help to reduce this backlog, while also tackling one of the sector’s main challenges – decarbonisation.

The new AMRC innovation facility in Sheffield has been developed to help solve composites manufacturing challenges in order to meet future demand for lighter commercial aircraft and help the aviation industry reach net zero. It aims to de-risk and develop high rate sustainable structures, with the potential to reduce large component process times from around 40 hours to approximately four hours. The facility is expected to be completed by the end of 2024.

The building will be home to a raft of state-of-the-art equipment secured through a £29.5m grant from the Aerospace Technology Institute (ATI) Programme to support new capabilities, technologies and processes to reduce cost, waste, production time and associated carbon emissions.

Boosting productivity

The five FANUC M-2000iA industrial robots that have been ordered by Loop Technology for the AMRC facility will form part of Loop’s proprietary high-rate deposition cell, known as FibreLINE. This state-of-the-art high rate preform manufacturing system, with FibreFORM at its centre, can pick composite sheets (plies) and form them into complex 3D double curvature profiles before placing them onto a tool, inspecting them and heat staking them ready for the next stage of the production process, at a rate of up to 200kg an hour.

Traditional methods typically operate at 40kg/hr, so this is a significant improvement. Meanwhile, the National Composites Centre, which uses a different configuration of FibreLINE that includes FibreROLL, has stated they are on track to deliver 350kg/hr.

Loop Technology has also ordered two further FANUC M-2000iA robots to form part of a separate FibreLINE system, for a key North American aerospace customer looking to carry out R&D applications. Once built, the entire FibreLINE system will measure more than 20m in length. It will centre around FibreFORM, a 3D double curvature preforming gripper that weighs more than one tonne, meaning that heavy-duty industrial robots with a high payload and long reach are essential.

With a 1.7 tonne payload capacity and 6.2m stroke, the M-2000iA/1700L provides maximum flexibility on operations involving large and heavy objects. Capable of lifting and positioning an entire car body, FANUC says it is officially the strongest long-reach robot in the world, making it the ideal choice for Loop Technology both for its North American aerospace client, and for the AMRC innovation facility.

“Being aero structures, the parts that are being manufactured on our FibreLINE systems are extremely large,” explains Alun Reece, managing director of Loop Technology. “These two projects therefore both require robots with high payload and reach capabilities to access all the areas necessary in order to carry out deposition or inspection activities. While we could have used precision gantries to deploy our end effectors, they limit access to the cell area due to requiring two rails on which to carry the gantry bridge. In contrast, the M-2000iA robots are mounted on a single axis rail, providing clear access from one side. They are our clear robot of choice for such projects.”

A solid partnership

Oliver Selby, head of sales for FANUC UK, has worked alongside Loop Technology for a number of years, helping to increase innovation in the aerospace sector. “We have been proud to have Loop Technology as one of our system integrator partners for the past five years,” he states.

“Their solutions, such as the FibreLINE and its constituent parts – FibreFORM (ply manipulation), FibreTACK (ply tacking) and FibreEYE (inspection) – are helping to increase automation uptake among aerospace manufacturers. Given the labour shortage within manufacturing as a whole and the extensive aircraft order backlog, higher levels of automation are essential to increase productivity and ensure the industry continues to thrive in the coming years.”

Alun Reece adds: “Innovations in robotics around scale, precision and collaborative working are opening up new opportunities for aerospace manufacturers all the time. Whether in high rate preforming systems, fibre placement, or assembly operations such as drilling, fastening, sealing or automated inspection applications, the versatility offered by modern robotics is redefining the way tasks are performed, helping to drive down aerospace manufacturing costs while driving up quality.”

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Visionic designs off-the-shelf optical guidance and control solutions for complex industrial manufacturing processes. As an integrator, it aims for constant improvement of industrial performance. Fuzzy Logic, with its no-code software that allows non-experts to create, simulate and control a robot cell in real time, aims to democratise industrial robotics.

Aeronautics is a demanding sector that requires extremely rigorous and standardized industrial processes. For example, machined engine parts must be rendered particle-free before assembly, and are therefore subjected to meticulous cleaning at very high pressure. These noisy and arduous processes are currently performed manually. Operators exposed to high pressure water jets, up to 60 bars, pollution and noise are at high risk of MSD. Aeronautical manufacturers and subcontractors are having difficulty recruiting candidates for these jobs, which are also highly regulated and whose difficulty is closely monitored by the unions.

In order to reduce the difficulty of these tasks, manufacturers are seeking to automate them. Nevertheless, they are confronted with the complexity of robotization, due in particular to the diversity of the parts and their number, to the expert costs and to the lack of availability of roboticists.

In response to these specific and complex problems, Visionic has designed a robotic cell that includes a chassis, a robot, high-pressure hydraulic circuits, a filtration system and a closed-circuit particle recovery system. It is controlled with Fuzzy Studio. Unique in the market, it allows the robotisation of these complex tasks, without expertise in robotic programming and at lower costs.

Generating robotic trajectories requires long and complex programming by a roboticist. Automation is even more complicated for applications such as high-pressure cleaning of aeronautical parts that involve a large number of parts with variable geometries. With Fuzzy Studio, these complex trajectories are automatically generated in a few clicks using 3D information from objects placed in a virtual cell. It is possible to add an unlimited number of waypoints to these trajectories. This feature saves users considerable time and frees them from dependence on robotics experts.

Xavier Savin, CEO of Visionic comments: “The key element of Fuzzy Logic’s software is its ability to generate automated trajectories, its simplicity and speed of execution. In this complex application, it introduces a radically new paradigm that is a major shift from classical systems that require a robotic operator. Here, the payoff for our customer is the conversion of a tedious, risky, non-value-added task to a basic operator task.”

Ryan Lober, CEO of Fuzzy Logic, explains: “With Fuzzy Studio, integration specifications are validated in minutes versus days or weeks and at lower costs. Cell sizing information is displayed for easy decision making, before moving on to real-time robot control with Fuzzy RTOS. Parameters can be quickly modified in the simulation. These advantages are unique in the market, and they allow to drastically reduce the investment risks of a robotics project. They offer the possibility to robotise where it seemed impossible.”

Xavier Savin adds: “Projects to reuse this cell are underway in the aeronautics sector. We are aiming further ahead and want to extend this solution to other industrial applications, for example welding or control. It is applicable wherever complex robotic trajectories need to be generated quickly.

“At Visionic, we are fully convinced of the interest of Fuzzy Logic’s software for our customers on the one hand but also for our R&D. It gives us a considerable technological advantage.”

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