Development of Large-Scale Structural Parts
About the Project
Project date:
2024
Industry:
Aerospace
Processes used:
Infusion
Part types:
Large-scale
structural parts
Challenges
Our client asked us to develop the next generation of their most important product.
- Increase production capacity
- Reduce part production costs
- Reduce environmental impact
Changes and Improvements to Meet Demand
Actions Taken
Modernization
Modernize part manufacturing technologies by transitioning from contact lamination (hand lay-up) to infusion manufacturing.
- Develop new methods
- Redesign structural parts
- Upgrade all tooling
Capacity Increase
Implement concrete actions to better address shortages of skilled labor.
- Develop skills of existing employees for use of new technologies
- Leverage new technologies to improve the work environment
- Optimize labor utilization at each stage of production
Recycled Materials
Use raw materials sourced from recycled materials.
- Develop new technologies and tooling to enable transformation of raw materials from recycled sources
Results
The new generation product is now in production
Modernization of manufacturing methods:
- Elimination of 2/3 of part manufacturing cycles
- 50% reduction in manufacturing cycle times
- 20% reduction in required labor
Near-total elimination of VOC (volatile organic compounds) during manufacturing:
- Reduced environmental footprint
- Improved employee comfort by eliminating the need to wear respiratory protection
Technology change and use of recycled material:
- 15% weight reduction for the entire project
- Parts manufactured with 25% fewer petroleum-based products
- 10% cost reduction
