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Aircraft wing resting on an assembly jig
Home/Sectors/Aerospace

aerospace sector

Tooling for machining and assembling aerostructure components: jigs, benches and large tables with tight flatness and position requirements.

Assembly jigsMachining fixturesFlatnessGeometrical tolerancesThermal expansionFEM analysisEN 9100

The work in this sector

An aerospace fixture is a measuring instrument before it is a structure: if it deforms, expands or loses its datum, the scrap is a high-value component. The design therefore starts from the tolerances of the part and from the way they will be inspected.

The studio designs tooling for aerostructure components, benches and large tables, with verification of stiffness, of flatness under load and of temperature effects, and with the documentation needed to qualify the tooling at the customer's.

What we design

Assembly jigsDatums, supports and clamps for panels, ribs and sub-assemblies, with the loading and unloading sequence of the part.
Machining fixturesFixtures for milling and drilling parts in light alloy and composite, with constraints that do not deform the part.
Benches and large tablesWelded or assembled structures with controlled flatness, adjustments and isostatic supports.
Stiffness checksFEM analysis of deflections under self-weight, working loads and temperature variations.
Dimensioning and inspectionGeometrical tolerances, datums and measuring points designed for inspection with a laser tracker or a coordinate measuring machine.
Qualification documentsDrawings, calculations, operating procedures and data for qualifying the tooling within the customer's quality system.

Reference standards

Before designing, the regulatory scope is defined: which standards apply, in which version and with which customer requirements.

EN 9100Quality management system for the aerospace sector: requirements that the customer passes on to tooling suppliers.
EN ISO 1101 / 5459Geometrical tolerances and datum systems: the language used to specify flatness and position.
EN ISO 14405 / 8015Dimensional tolerances and the basic principles of geometrical product specification.
EN 1993-1-1 / 1-8Verification of steel structures and of the connections of benches and frames.
EN 1999-1-1Aluminium structures, when the tooling has to be light or moved around.
EN 1090-2Execution class and manufacturing requirements for welded structures.
Directive 2006/42/ECWhen the tooling has powered parts or movements, it falls within the scope of machinery.
Customer specificationsMaterials, treatments, cleanliness and markings required by the aircraft manufacturer.
Versions in force

Standards are revised fairly often: the first activity in every project is to check which edition applies at the date of the design.

How we work

  1. Part and tolerancesGeometry, datums, tolerances, materials and inspection method of the component.
  2. Constraint schemeSupports, datums and clamps chosen so as not to deform the part and to be repeatable.
  3. Design and FEM3D model, verification of deflections under load and with temperature, selection of materials.
  4. Drawings and inspectionDimensioned drawings with geometrical tolerances, measuring points and inspection procedure.
  5. QualificationSupport during dimensional acceptance and for the documentation required by the customer.

What you receive

3D model of the toolingDrawings with geometrical tolerancesBill of materialsFEM stiffness reportThermal verificationInspection planOperating procedureQualification documents

Images

Wing assembly jig
Wing assembly jig
Machining centre
Machining centre
Dimensional inspection
Dimensional inspection
Structure of a bench
Structure of a bench

FAQ

Do you also design tooling for composite parts?

Yes. The constraints change, because the composite must be neither deformed nor marked, and the expansions between part and tooling change as well.

Can you check the flatness of an existing bench?

Yes, with a FEM analysis of the structure under the real loads and, if needed, the modifications required to come back within tolerance.

Do you work within the customer's EN 9100 quality system?

Yes: formats, revisions and documents follow the procedures the customer passes on to its suppliers.

Let's talk about your project

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aerospace sector

Tooling that holds tolerance, even under load

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