Automated ply placement (APP). Source (All Images) | Airborne

At Airbus headquarters in Toulouse, France, and in the presence of King Willem-Alexander and Queen Máxima of the Netherlands, Airbus Helicopters has signed a letter of intent (LOI) to adopt Airborne’s (The Hague, Netherlands) digital automation technologies for its factory in Le Bourget, France. The goal is to optimize manufacturing efficiency and output of composite rotor hubs and helicopter blades through implementation of both Airborne’s main software and automation systems, automated ply placement (APP) and Kit by Light (KBL), respectively.

The focus will be on new automation and software to boost productivity and efficiency. Airbus’ Le Bourget factory makes all composite helicopter blades and hub structures for all Airbus helicopter models, both military and civil. “It's a high-mix production environment, ramping up to meet increasing demand, and Airborne’s industrialization technologies are an excellent fit,” says Marcus Kremers, CTO of Airborne. 

APP is already used by Airbus Commercial for the A350 program. It automates the layup process from cutter to laminate and can be used for prepreg and dry fiber, both of which are processed in Le Bourget (read “Modular, robotic cells enable high-rate RTM using any material format”). In this project, new features regarding part size, layup and quality inspection are planned to be added.

Kit by Light (KBL).

KBL is already in use at Airbus Helicopters’ sister plant in Donauwörth, Germany, where it supports operators in the cutting room with software that significantly accelerates kitting. Building on that experience, plans are to implement the system in the Le Bourget factory to reduce material waste and increase output.