The aerospace manufacturing industry is taking off, with sustainability as its new North Star. By integrating smart tools and leveraging the power of automated, connected smart factories, the industry is reducing waste, optimising energy use, and improving efficiency across production lines. These innovations are not only helping manufacturers meet stricter environmental standards and stakeholder expectations, but also paving the way for a brighter aviation future.
Aviation plays a key role in pressing global challenges
The aerospace sector plays a critical role in the UK economy. As the second largest aerospace industry globally, the UK’s aviation sector is vital for the country’s economic output and its strategic position in space and defense. However, this importance also places it at the centre of one of the most pressing global challenges: decarbonisation.
With aviation emissions projected to make it one of the largest emitting sectors by 2050, achieving net-zero flying has become a pivotal goal. The UK government’s Jet Zero strategy, which aims for net-zero aviation by 2050, sets a high bar. The challenge is compounded by the rapid recovery of the international aviation market post-pandemic. Customers, partners and governments are increasingly requiring industrial manufacturers to minimise their environmental impact. With time running out, sustainability is no longer a “nice to have”. It is a matter of corporate survival.
The time to act is now
We are at a turning point when action needs to be taken and addressing challenges will require a transformative approach to aerospace manufacturing. At the heart of this transformation is smart manufacturing, which integrates digital technologies throughout the production cycle. Here’s how smart manufacturing plays a part in the journey to decarbonising aviation:
1. The transition to electric smart tooling
Traditionally, the aerospace industry has relied on pneumatic tooling and manual torque wrenches to ensure joint integrity. In the drive towards decarbonisation and traceable, sustainable operations, a phased transition to electric and battery-powered smart tooling delivers a compelling proposition.
Although the needs of a specific application determine the optimal tooling solution, there are a number of advantages of using electric and battery tools over legacy pneumatic ones.
Pneumatic tools require more infrastructure, including compressors and air hoses to operate them. As well as taking up space, this also requires ongoing maintenance and monitoring. In comparison, battery-powered assembly tools and drills eliminate the tripping hazards associated with airlines. Being cordless allows battery tools to be used without restrictions in areas such as airframe assembly, enabling operators to perform better.
Switching to electric DC tools with a consistent power source allows manufacturers to improve their sustainability efforts by achieving high productivity rates for less energy consumption. The more efficient processes are, the lower the carbon footprint, which contributes to better environmental performance for the industry and the organisation.
Atlas Copco’s advanced electric assembly technology tools have been developed to provide manufacturers with a starting point in the journey toward transformation. They remove the need for multiple tools by providing a joint integrity check and data collection for a specific assembly process. Covering every aerospace application, the tools offer error-proofing features that air tools typically do not possess, such as the ability to utilise definable tightening programs to ensure bolt-level accuracy. They are also designed with ergonomic innovations such as a dual trigger for user safety, and they are lighter in weight to make them easier and more pleasant to use.
2. More sustainable practices with smart design and materials science
Smart manufacturing drives innovation in aerospace by fostering collaboration among manufacturers, suppliers and stakeholders. This leads to faster development and adoption of advanced solutions. The impact of smart manufacturing extends beyond manufacturing processes to areas like product design, materials science and other sustainable practices. This helps to keep the aerospace sector at the forefront of technological advancement.
Inspection technology such as Atlas Copco’s ISRA vision systems can be employed in the production process to ensure traceability and quality assurance. For example, the efficient SMASH inline inspection system enables sheet materials such as composites to be inspected in real-time, with defects detected and classified to ensure material quality.
3. Real-time data insights create more sustainable manufacturing
Smart manufacturing integrates data analytics and AI to turn vast amounts of production data into actionable insights. This data-driven approach enables full traceability throughout the assembly process, optimising production lines, identifying bottlenecks and enhancing overall operational efficiency. Real-time monitoring through smartphone apps and predictive analytics platforms, like ALTURE, empowers manufacturers to make proactive decisions. These capabilities not only minimise downtime but also improve resource utilisation, ensuring smoother operations and reduced waste.
Efforts such as electrification, carbon footprint reduction, and waste minimisation are increasingly supported by data-driven technologies. What gets measured gets managed: Atlas Copco’s CO2 calculator exemplifies this shift by helping manufacturers measure their current environmental impact and identify opportunities for improvement.
Supporting the transition of the aerospace industry from traditional assembly and maintenance tooling and processes into the age of smart manufacturing with 100% traceability is a priority for Atlas Copco. With experience and best practices gathered from decades of work in various industries, we can guide your way to a more sustainable future.
Want to learn more about our offering and how Smart Integrated Assembly can transform your operations? Discover our Smart Factory offerings here.
