A UK-Led Novel Technology For Aerospace Manufacturing Will Slash Forming Cycle Times By Over 50% and Manufacturing Costs by 25%.

Aviation is considered one of the leading emitters, accounting for approximately 2.5% of global CO₂ emissions. In the quest for enhanced manufacturing capabilities and heightened efficiency within the aerospace industry, a groundbreaking hybrid manufacturing method has emerged, poised to redefine the production landscape for critical aerospace components.

Shropshire-based SME SDE Technology is spearheading this transformative initiative, marking a significant milestone towards unparalleled advancement in aerospace manufacturing.

The pioneering development will be a novel superplastic forming process, signalling a paradigm shift in aerospace manufacturing methodologies. This endeavour, which is part of the National Aerospace Technology Exploitation Programme (NATEP) and the prestigious Advanced Forming Research Centre (AFRC) within the National Manufacturing Institute Scotland (NMIS) Group operated by the University of Strathclyde will be a vital cog in the High-Value Manufacturing Catapult (HVMC). 

The transformative venture is supported by industry giants Boeing and Timet UK, who will offer technical expertise and business activities.

Superplastic forming, renowned for its precision in crafting thin-sheet metallic components, has long been the cornerstone of aerospace manufacturing, particularly in the creation of intricate titanium parts. However, the advent of a revolutionary hybrid technique promises to revolutionise this landscape. Compared to traditional methodologies, it is poised to slash forming cycle times by over 50% and manufacturing costs by a staggering 25%. 

Armed with innovative tooling solutions, this pioneering approach will mark a new era of efficiency and agility in aerospace manufacturing, empowering SDE Technology to unlock the aerospace market's potential while fortifying the UK's position as a bastion of high-value titanium component manufacturing.

According to Evgenia Yakushina, forming team lead at the Advanced Forming Research Centre, the transformative potential of this collaborative endeavour will usher in a new dawn for aerospace manufacturing and catalyse industry-wide transformation, propelling manufacturers towards novel, expeditious methodologies for aircraft component production.

The ongoing research by the Aerospace Technology Institute (ATI) programme through NATEP seeks to validate the hybrid technique's scalability for aerospace applications. It will involve testing the commitment to maintaining stringent quality standards and tolerances synonymous with traditional superplastic forming. 

Additional funding has already been earmarked to evaluate the environmental footprint of this pioneering process, poised to significantly mitigate carbon emissions through reduced heating and forming times alongside lower operating temperatures. 

The novel approach will help aerospace component manufacturers circumvent the challenges posed by conventional superplastic forming. Conventional superplastic forming notably forms an oxide layer alpha case on titanium components under high temperatures, necessitating arduous removal procedures. By harnessing reduced heat input, the new methodology not only mitigates alpha case formation but also streamlines removal processes, epitomising efficiency and sustainability in aerospace manufacturing.

The CEO of SDE Technology, Richard Homden, points out that the transformative potential of this collaborative venture will herald a new era of manufacturing excellence within the aerospace sector. It will also allow the company to carve a niche in the aerospace supply chain, epitomising British ingenuity and innovation on a global stage.

The sentiment is supported by David Milliken, technical lead for forming and forging at Boeing who underscores Boeing's commitment to fostering innovation in aerospace manufacturing and points out that this collaborative endeavour embodies a shared vision of advancement and excellence, poised to reshape the aerospace landscape for generations to come.