New generation of robotic cells to drive zero-emission aerospace manufacturing

The aeronautical industry has dual objectives: achieving net-zero emissions by 2050 and improving competitiveness by reducing production costs. However, this goal is hampered by reliance on heavy, expensive, and inflexible machinery in manufacturing processes

To address this situation, the technology centre IDEKO has contributed to the development of a new generation of flexible, sensorised and connected robotic cells within the framework of the ROBOCOMP project. Led by the DANOBAT cooperative, this initiative aims to transform the manufacturing processes of aeronautical components.

Asier Barrios, the centre’s researcher, said, "The new solutions are designed to replace traditional systems and automate critical machining operations on carbon fibre parts, such as milling, drilling and trimming, in order to boost efficiency and reduce energy consumption.” 

This technological transition responds to the specific operational limitations of current machinery. While large traditional equipment usually machines parts in a horizontal position, restricting access to several components with complex geometries, ROBOCOMP’s proposal enables vertical machining.

This feature also enables scalable production, allowing plants to adapt quickly to new manufacturing requirements.

Precision and monitoring

The technology centre, a member of the Basque Research and Technology Alliance (BRTA), has provided intelligence for these new solutions. Specifically, IDEKO’s scientific work has focused on improving robot precision through mechatronics and system calibration, which are essential for meeting the strict requirements of the aerospace sector.

Additionally, the centre has equipped these cells with the intelligence needed to operate autonomously. Using artificial vision systems and sensors, the robots can see and analyse the status of the manufacturing process as it occurs. This digitalisation enables the process to be monitored in real time, instantly identifying possible errors or deviations to ensure the quality of the part.

Sustainability has also been addressed within the initiative through the implementation of technologies that optimise the machining of composite materials, ensuring more efficient use of energy and resources.

Transfer to other sectors

The initiative's success has been supported by a robust industrial consortium spanning the entire value chain. Alongside the leadership of DANOBAT and the scientific knowledge of IDEKO, the project has benefited from the participation of Airbus, which has contributed the end user’s vision and requirements; Robotnik, a European specialist in mobile robotics; and Industrial Olmar, a company focused on the manufacture of autoclaves and pressure equipment.

This collaboration has facilitated the development of technologies that position the Basque and Spanish industrial fabric at the forefront of advanced manufacturing, with a clear drive to expand into other markets.

The technologies developed at ROBOCOMP will be transferable to other machining-intensive sectors, including automotive, energy and capital goods, reinforcing the competitiveness of small and medium-sized enterprises and opening new business opportunities in advanced services and smart maintenance.

The project has been funded by the Centre for the Development of Industrial Technology (CDTI) through the Aeronautical Technology Programme (PTA), a grant framed within the Recovery, Transformation and Resilience Plan of the Government of Spain.