AEROSUD: New Heights in Aircraft Component Manufacturing

Harnessing the wealth of expertise boasted by its 500 employees and the collective know-how garnered over a more than 30-year history, Aerosud’s aerostructure and aircraft components are trusted by some of the true giants of the industry.

“Aerosud is well known to be the Swiss Army knife of extended manufacturing capability, and always supportive of emergent customer requirements in industrialising new products,” says Pilatus Aircraft, a viewpoint shared by Airbus Defence & Space: “Aerosud is technically agile in specialised manufacturing solutions; it is our manufacturing partner for the long-term offering innovative technology-driven solutions.”

MULTIFACETED MANUFACTURE

Such lofty billing does not come by accident, of course; it is earned only through rigorous processes, a peerless project portfolio and a policy of continuous development and improvement.

Aerosud’s metallic fabrication covers the full spectrum from traditional hand-formed parts to complex press-formed parts. “All associated tooling is designed in-house,” the company furthers, “with the design process making use of simulation software to ensure it is right first time.

“Our supply chain network includes a large number of South African-based tooling manufacturers.” In-house capability includes 3-axis and 5-axis machining and our well-established local network of world class machining suppliers includes the capability to machine hard metals. “We also manufacture simple as well as complex geometry parts,” Aerosud says, “using materials ranging from polycarbonates to Continuous Fibre Reinforced Thermoplastics (CFRTP).

“Our in-house capability allows us to manufacture CFRTP parts up to 1m x 2m in size.”

On the composite manufacturing side, Aerosud’s competences include both oven and autoclave cured parts with an on-site autoclave enabling the manufacture of parts up to a diameter of 1.5 metres and length of three metres. “We complement our traditional composite manufacturing know-how with our patented technology, known as Cellular Core Technology (CCT),” explains Aerosud. “This unique manufacturing process results in significant weight and cost reductions.

“Our composite facility includes a material testing laboratory where we are able to perform chemical analysis, thermal analysis, thermo-mechanical testing as well as mechanical testing at elevated temperatures.” Expertise and OEM approvals in various joining technologies, such as adhesive bonding and riveting and fastening, means that Aerosud is able to manufacture complex assemblies from detailed parts, while robotic welding cells provide significant capacity to absorb production rate increases.

NEW TECHNOLOGIES

“We are built on passion,” Aerosud summarises. “We take that passion and develop it, with more than 600 pairs of hands building aircraft parts and more than 600 voices communicating daily. We are an African solution, focusing on partnerships and collaboration.” In order to remain the first-choice African provider, as well as to ensure the continuous provision of a competitive total cost of business in the global aerospace market, Aerosud has in recent years consistently invested in the development of multiple technology streams, including those connected to Industry 4.0.

One particular development, a patented technology known as cellular core technology (CCT), paves the way for the manufacture of highly complex assemblies in one single piece; the result is significant reductions in part count as well as assembly time, which in turn reduces overall cost and weight.

Traditionally, assembly of aircraft structures is complex and comprises costly machined metallic parts that are fastened together using large quantities of metallic fasteners, labour intensive assembly methods as well as expensive assembly jigs. The contemporary requirement for lighter and, therefore, fuel-efficient structures, has led to a significant increase in the use of composite materials in the latest generation aircraft structures.

“For Aerosud to remain a relevant supplier in the aerostructures supply chain, we have over the past number of years invested in a unique manufacturing and tooling technology specifically developed for structural composite parts,” the company responds.

“The uniqueness of CCT is in the tooling methodology used for manufacture of the part. To date, CCT has demonstrated the ability to achieve a reduction in part count of up to 75% together with a weight reduction exceeding 20%. Customers have reported on an estimated cost reduction of up to 30%,” Aerosud sums up, with its forward-thinking ethos and renowned nurturing and support of industry talent set to keep it soaring long into the future.