The A380, Leader on Manufacturing technology

FARNBOROUGH20th/21st July 2004

Neil HARRIS

Presented by

Airbus – A Leader in Manufacturing Techniques2

AIRBUS CONTINUES TO MAINTAIN ITS LEADERSHIP ON ADVANCED TECHNOLOGIES IN MANUFACTURING

Key steps in fabrication High speed cutting Composites Joining technologies

Key steps in Assembly Automated Advanced positioning Jig less

The A380, Leader on Manufacturing technology

Airbus – A Leader in Manufacturing Techniques3

Production across the family High cutting volume All metals & composites Sophisticated work piece geometry

with thin walls due to lower cutting forces

Supported by simplified tooling

High performance cutting offers significant cost reduction whilst ensuring minimal waste.

A380 – Leader on …HIGH SPEED CUTTING

Airbus – A Leader in Manufacturing Techniques4

Nearly 20 years experience in primary structures

Most advanced tape laying capability and resin transfer moulding (RTM) for integrated parts

Ultrasonic scanning systems

Elements with high load resistance

Airbus sets the standards for efficient manufacturing of high load composite parts.

A380 – Leader on …COMPOSITE PRIMARY STRUCTURES

Airbus – A Leader in Manufacturing Techniques5

Components with carbon fibre resin infusion New components in resin film

infusion and advanced layer technology

Application to complex curved parts (example pressure bulkhead)

Extension of Carbon Fibre Manufacturing technologies to new components reduces aircraft weight.

A380 – Leader on …COMPOSITE PRIMARY STRUCTURES

Weight savings = less fuel consumption

= less emissions

Airbus – A Leader in Manufacturing Techniques6

Large parts and complex shapes Optimum ply distribution First application on A380

(A380 rear section)

Leader in composite applications.

Solutions for complex fibre elements

A380 – Leader on …COMPOSITE PRIMARY STRUCTURES

Airbus – A Leader in Manufacturing Techniques7

Fuselage Panels Laser beam welding for integrated panels

(lower and side fuselage shells) On-line quality control Elimination of fasteners – reduces weight

and reinforces structure

A380 – Leader on …LASER BEAM WELDING

Welding offers further improvements to the manufacturing of fuselage shells (example weight reduction).

Airbus – A Leader in Manufacturing Techniques8

New generation of riveting and flexible tooling system drives further cost and cycle time reduction.

High performance automated riveting cells for skin panels and “super-shells”

Chord dimensions up to 11 m / 35 feet

Skin Panel and Shell Riveting Machines

A380 – Leader on …AUTOMATED PRODUCTION SYSTEMS

Airbus – A Leader in Manufacturing Techniques9

Wing Skin Panel Assembly Automation of wing skin

assembly in flexible build station

Dimensions up to 136 m / 450 feet

Automated fastening systems offer additional flexibility and increased output.

A380 – Leader on …AUTOMATED PRODUCTION SYSTEMS

Airbus – A Leader in Manufacturing Techniques10

Avoid requirements for heavy jigs Reduces floor space Improves lead time

Laser positioning, best fit methods

Advanced positioning optimises work space and improves flexibility across programmes.

A380 – Leader on … ADVANCED POSITIONING METHODS

Airbus – A Leader in Manufacturing Techniques11

Fuselage Assembly Stations Multi-type “jig less” flexible

assembly process on aircraft sections

Jig less tooling offers a highly flexible concept that can react to changing demands.

A380 – Leader on …JIG LESS FLEXIBLE ASSEMBLY

Airbus – A Leader in Manufacturing Techniques12

Key steps in fabrication High speed cutting Composites Joining technologies

Key steps in Assembly Automated Advanced positioning Jig less

The A380, Leader on Manufacturing technology

Benefits Cost efficient and productive High quality Improved flexibility Environmentally friendly Always “Safety first”