Ireland: Taking flight with aerospace innovation

Aircraft manufacturing faces a complex challenge of misalignment and inefficiencies in wing panel assembly caused by variability in components. Innovating in robotics and automation, Irish institute, Irish Manufacturing Research, is improving precision and reducing the cost of wing production for major aircraft manufacturers.

Irish Manufacturing Research launched the Eureka MAAS project through Eureka’s Cluster SMART, partnering with Irish and Spanish organisations, TEG, Airbus and Robotnik. Together, they developed a mobile robotic 3D scanning and digital matching system that inspects entire aircraft wings and identifies optimal panel fits. This system automates assembly, quality assurance and stiffener integration, amongst other processes.

During the MAAS project, an entire Airbus wing made it to Irish Manufacturing Research’s facilities, allowing the aerospace company to see how the end-to-end robotic assembly system works without altering its existing infrastructure. The project team discovered the system is so precise that it can identify the best-fit wing panel in seconds, a task that previously took hours of manual inspection.

The MAAS project created real business-to-business opportunities and showcased Irish small- and medium-sized enterprises at the highest level of aerospace innovation.

Ken Horan – Director of Robotics and Automation at Irish Manufacturing Research

Irish Manufacturing Research’s motto is “demystify, derisk, deliver”, which it achieves by helping industry leaders adopt sustainable manufacturing solutions offered by small- and medium-sized enterprises in Ireland. The institute serves as a launchpad for validating research propositions on-site and showcasing technologies to potential stakeholders in the manufacturing ecosystem.

Eureka, SMART and Enterprise Ireland facilitated the project and partnerships, enabling collaboration across borders and sectors and ensuring alignment with industry needs. The project catalysed high-impact partnerships between small- and medium-sized enterprises, research institutes and a global aerospace leader, leading to increased exposure, credibility and business opportunities for the smaller companies. The success of MAAS highlights the strength of Irish innovation and the value of strategic partnerships in advanced manufacturing.

The MAAS project has had a tangible impact on the aerospace industry: its high-speed, high-accuracy robotics system is improving manufacturing efficiency whilst reducing manual errors and operational costs from reassembly. In addition, the project has advanced Ireland’s capabilities and position in aerospace innovation. Overall, the project is a compelling example of how international collaboration and targeted research can drive real-world industrial transformation; with new robotics automation, the aerospace sector and Ireland’s small- and medium-sized companies are set for a smooth flight.