Britain’s Team Tempest consortium now has hundreds of millions of pounds invested in technology studies and development work to prepare the resulting next-generation combat aircraft to fly in the battlespace of the 2040s.
Nonetheless, long before the platform reaches contested airspace it will be challenged by the complexity of how to build such an advanced platform both quickly and affordably.
—the leading member of the Team Tempest consortium, which also includes Leonardo, MBDA and
—has begun looking at new manufacturing techniques and technology that will not only apply to work on Tempest but potentially also existing programs such as the
and
as well.
Current manufacturing processes, such as drilling 150,000 holes in and around the fuselage and wings of the BAE Systems Hawk jet trainer, or the Typhoon’s moving production line, are too slow for what is envisaged for Tempest, said Andrew Schofield, BAE’s director of manufacturing and materials, speaking earlier in August.
He said future production methods will need to be leaner and more productive.
“When you take the length of time from concept and bringing Typhoon to service, we are looking to halve that time across the whole organization,” said Schofield.
“We will not be producing at the volumes associated with
,
or even the F-35, so we have got to be more flexible,” he added.
In a building a short walk from where the last British Typhoons are being assembled, BAE has established a laboratory for its factory of the future concept. The idea is based on greater use of digitalization and big data, as well as so-called “cobotics,” which calls for human operators working alongside robots.
“The challenge of Tempest is that it has to be connected, upgradable, flexible and affordable. And when you translate those requirements, you need a factory of the future,” said Schofield.
Unlike in a car factory, where robots will perform one task on a rolling production line, BAE envisions the use of reconfigurable assembly cells using robots that can be programmed to perform several different tasks as the assembly process progresses.
Rather than using costly tooling and jigs, the robots will be able to hold large aircraft structural components in place as assembly progresses.
Technology such as additive manufacturing has the ability to reduce manufacturing lead times. The company has already proved it can produce components that would normally have a lead time of 100 weeks, not to mention components that can be produced and ready to be fitted to the aircraft, in just 100 days
.
The move is a step beyond the laser-alignment technology that BAE installed on the Typhoon assembly, which means UK Typhoons are slightly more fuel efficient than those assembled elsewhere in the program.
The company also wants to make use of the digital twin concept, in other words mapping and collecting data on individual components so that a virtual representation of the component can be recreated.
In the coming weeks, the company plans to produce a large piece of a representative Tempest fuselage demonstrating different manufacturing and joining techniques.
BAE is already working with academia, including universities in Birmingham, Bristol and Manchester, as well as the Sheffield, England-based Advanced Manufacturing Research Centre and companies including Stratasys and Siemens.
The company has also developed an advanced workbench, or collaborative workstation, where employees will liaise with robots on the assembly. The bench is capable of self-adjusting to the comfortable working height of the operators, while the systems can be customized to their skill level. Someone new to the role could be given extra steps to complete the task, whereas more experienced operators would see fewer.
Workers would also have a direct connection with engineers through a camera and projection system that will be capable of showing how components should look during the various steps. The system will even warn operators through a process called “pick by light” if they try to take and install the incorrect component. The aim is increasing productivity, as well as reducing and ensuring that components are assembled correctly the first time.
Two of the workbenches are already being used in F-35 component production.
In addition to manufacturing, BAE is exploring the use of multifunctional materials, usually composites that can embed aircraft systems within it. Schofield said the company has experimented with such materials that can be used as batteries to store electrical charge for onboard systems. Sensors can also be embedded in the material for signature control and sensing. The company is also continuing its research into materials with low-observable (LO) attributes. The company’s research is exploring LO materials with a lower weight and maintenance penalty, but also those that operate across wider frequency bands.