Short answer

Designers and manufacturing engineers should explore integrating advanced metrology and robotic systems with additive manufacturing to create more agile and cost-efficient assembly processes for complex products.

Field: Final Production
Source: Warwick Research Archive Portal (University of Warwick) (2021)
Method: Experimental demonstrator and case study analysis.
Evidence: Strong effect

Employing metrology-guided robots and additive manufacturing for shims can significantly reduce the time and cost associated with assembling complex structures like aircraft airframes. This final production research insight is drawn from a 2021 study published in Warwick Research Archive Portal (University of Warwick). Using Experimental demonstrator and case study analysis., researchers explored how this design variable affects real-world outcomes. The key design takeaway: Designers and manufacturing engineers should explore integrating advanced metrology and robotic systems with additive manufacturing to create more agile and cost-efficient assembly processes for complex products.

Study

Final ProductionHigh ImpactStrong effect

Automated Metrology Guides Robotic Assembly for 50% Faster and Cheaper Aircraft Production

Employing metrology-guided robots and additive manufacturing for shims can significantly reduce the time and cost associated with assembling complex structures like aircraft airframes.

Warwick Research Archive Portal (University of Warwick) · 2021

Key Findings

01Metrology-guided robots can position parts with tolerances comparable to traditional welded steel fixtures.
02Robotic positioning can be maintained for extended periods and reconfigured for assembling different parts.
03Drilling parts during manufacturing, using conventional or angle-head tooling, facilitates assembly and reduces reliance on craft-based fitting skills.
04Interface data collected during part manufacture can be used for subsequent processes, such as generating additive manufactured shims.

Application

Design takeaway

How to apply

When designing complex assemblies, consider how real-time measurement data can guide robotic placement and how additive manufacturing can create custom-fit components for precise joint assembly.

Project actions

01Consider how measurement tools (like calipers, CMMs, or even cameras) can inform the placement of components in your design.
02Explore how 3D printing can be used to create custom jigs, fixtures, or even final parts that adapt to slight variations in other components.

Method & Evidence

AimTo investigate the use of automation, including Measurement Assisted Assembly (MAA) and predictive processes, to reduce the acquisition cost of fast-jets by enabling faster manufacturing and reconfigurable automation.

MethodExperimental demonstrator and case study analysis.

ProcedureA one-to-one scale demonstrator of an airframe section was designed, manufactured, and assembled using MAA. Measurement data collected during manufacturing was used to produce additively manufactured shims for structural joints. The study also analyzed the UK-MOD's acquisition process and global automation trends in airframe assembly.

ContextAerospace manufacturing, specifically fighter jet airframe assembly.

Variables

IV["Use of metrology-guided robots vs. traditional assembly methods.","Use of additively manufactured shims vs. traditionally fabricated shims."]

DV["Assembly time.","Assembly cost (inferred from time and tooling).","Accuracy of component placement/joint fit."]

CV["Complexity of the airframe section being assembled.","Type of materials used for components.","Environmental conditions of the assembly area."]

Strengths & Limitations

Strengths

+Demonstrates a novel application of existing technologies (metrology, robotics, additive manufacturing) for a specific industrial problem.
+Provides quantitative findings related to cost and time reduction goals.

Limitations

The complexity and cost of implementing such automated systems in a small-scale project can be a significant barrier.

Reliability & validity

The reliability would depend on the precision and calibration of the metrology equipment and robots. Validity is supported by the comparison to established industry standards (welded steel fixtures) and the achievement of specific cost/time reduction targets.

Think critically

What are the potential failure points in a system that relies so heavily on automated measurement and robotic action, and how can these be mitigated?

Design Principles

"Automated metrology and robotic manipulation enable flexible, high-precision assembly, reducing reliance on fixed tooling and craft skills."

The traditional methods for assembling aircraft airframes are costly and inflexible, leading to escalating acquisition expenses. This research demonstrates how automation, specifically using metrology-guided robots and on-demand additive manufacturing, can create a more adaptable and cost-effective production environment, aligning with the goals of next-generation defense programs.

What This Means for Your Design

Using robots that 'see' with precise measurement tools and 3D printing custom parts can make building things like airplanes much faster and cheaper.

How to use in your project

1.Reference this study when discussing how automation and new manufacturing techniques can improve efficiency and reduce costs in your design project.

Add to My Project

Quick Cite

Paragraph starter

Research by Carberry (2021) highlights the potential of metrology-guided robots and additive manufacturing to revolutionize assembly processes. By using precise measurement data to direct robotic placement and 3D printing custom-fit components, significant reductions in assembly time and cost, as seen in aerospace applications, can be achieved. This approach offers a pathway towards more flexible and efficient manufacturing.

Source

Warwick Research Archive Portal (University of Warwick)

Reducing the acquisition cost of the next fighter jet using automation

journal · 2021

View source

Questions About This Research

What does the research say about automated metrology guides robotic assembly for 50% faster and cheaper aircraft production?: Designers and manufacturing engineers should explore integrating advanced metrology and robotic systems with additive manufacturing to create more agile and cost-efficient assembly processes for complex products. Evidence: Warwick Research Archive Portal (University of Warwick) (2021).
Why does "Automated Metrology Guides Robotic Assembly for 50% Faster and Cheaper Aircraft Production" matter for design?: The traditional methods for assembling aircraft airframes are costly and inflexible, leading to escalating acquisition expenses. This research demonstrates how automation, specifically using metrology-guided robots and on-demand additive manufacturing, can create a more adaptable and cost-effective production environment, aligning with the goals of next-generation defense programs.
How can designers apply this research?: Designers and manufacturing engineers should explore integrating advanced metrology and robotic systems with additive manufacturing to create more agile and cost-efficient assembly processes for complex products.
What were the main findings?: Metrology-guided robots can position parts with tolerances comparable to traditional welded steel fixtures.. Robotic positioning can be maintained for extended periods and reconfigured for assembling different parts.. Drilling parts during manufacturing, using conventional or angle-head tooling, facilitates assembly and reduces reliance on craft-based fitting skills.. Interface data collected during part manufacture can be used for subsequent processes, such as generating additive manufactured shims.
What research method was used?: Experimental demonstrator and case study analysis..
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2021 journal from Warwick Research Archive Portal (University of Warwick).
What should I do differently in my next project?: When designing complex assemblies, consider how real-time measurement data can guide robotic placement and how additive manufacturing can create custom-fit components for precise joint assembly.
What are the limitations?: The study focused on a specific demonstrator and may not fully capture the complexities of full-scale production or the integration challenges across an entire manufacturing facility.