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Resin transfer molding (RTM) is gaining importance as a particularly economical manufacturing method for composites needed in the automotive and aerospace industries. With this method, the component is first shaped with dry fiber reinforcements in a so-called “preforming process” before the mold is placed in a RTM tool, injected with resin and cured. In recent years, Broetje-Automation has been developing innovative product solutions that are specially designed for these preforming processes and suitable for industrial use. For the first time ever, Broetje’s Composite Preforming Cell (CPC) makes large-quantity serial production of complex and near-net-shape preforms for composite components using this RTM process possible. With the additional integration of the patented 3D Composite Handling System Broetje impressively demonstrates its service and product portfolio in the area of innovative composite manufacturing technology and its know-how as a complete system integrator.

The demand of fulfilling continually increasing customer requirements forces suppliers to always improve their system solutions to be state of the art. The subject Project Management Approach explains the planning and realization of complete Integrated Assembly Lines for Aircraft structural parts and components. The paper will describe and focus on the main aspects of the state of the art technology in automated fastening, drilling and assembly processes to meet the required customer production and reporting criteria. Furthermore the paper will present existing production examples in support of the established project management process.

The demand to produce aircraft structures with new materials, at acceptable investment levels, without restricting product quality or equipment reliability prompts suppliers and customers to think about new concepts for production processes. The manufacturing system in this paper, for a Fixed Trailing Edge Assembly Facility, combines traditional manual manufacturing processes with highly automated machinery. The introduction of a flow process, with moveable assembly jigs, enables high production rates with optimized operating times of the equipment. The system also provides the flexibility to handle different aircraft variants. This paper is intended to focus on the main aspects of the state of the art technology of the manufacturing system and shall explain the integration of such a system from the design phase to the operational launch in an actual aircraft program.