Airborne to deliver automated preforming line to GKN Aerospace

GKN Aerospace (Redditch, U.K.) has selected Airborne (The Hague, Netherlands) to supply a fully automated preforming line to its Global Technology Centre located in Bristol, U.K. The system will integrate an automated ply placement (APP) cell by Airborne, automated preform trimming by Accudyne Systems (Newark, Del., U.S.), a ply cutter from Assyst Bullmer (Wakefield, U.K.) and a hot drape former by PAC Group (Belfast, Ireland).

The system will reportedly transform broad goods such as woven or noncrimp fabric (NCF) materials into 3D preforms suitable for resin transfer molding (RTM). Cut shapes can be optionally stored in Airborne’s buffer enabling “out-of-sequence” nesting, minimizing material waste and improving cost and sustainability. Plies will be assessed using a vision system and then via “pick and weld” assembled into 2D tailored blank preforms. These will be 3D formed by the hot drape former and then trimmed to shape on the trimming cell.

Each sub-system will be integrated by Airborne into its Automated Programming software platform. Through this solution, each device can be operated standalone — however, in automated mode, the system will translate design and process input into individual controls and robot code without the need for programming. The system will generate instructions on the fly, Airborne notes, enabling flexible manufacturing.

The system will initially be deployed to fulfill objectives in the ASCEND project, in which GKN Aerospace is leading the U.K. industry consortium. The program aims to develop and accelerate composite material and process technologies for the next generation of energy-efficient aircraft and future mobility.

The £40 million consortium, funded by a £20.0 million commitment from industry and a £19.6 million commitment from the UK government via ATI, will focus on greater adoption of composites technologies, the industrialization of new technologies, as well as accelerating aerospace production rates to meet future high-volume requirements. The collaboration will help develop technologies from across the U.K. supply chain to develop the advanced materials and automation equipment required to manufacture lightweight structures for sustainable air mobility, aerospace and automotive. The new automated preforming cell from Airborne will provide the capability to manufacture next-generation components for the aerospace market.

“This major commitment from GKN Aerospace to Airborne’s technology further supports our goal to offer flexible automation solutions and workflow automation enabling higher rate manufacturing of composite structures,” Joe Summers, commercial director of Airborne and managing director of Airborne UK, notes.