46 AEROSPACEMANUFACTURING
FINAL APPROACH I
Good advice
As Chairman of the UK’s National
Advisory Committee for Aerospace
Manufacturing (NACAM), Steve
Johnston provides an overview of the
Committee’s purpose of advising on
future development
Steve Johnston | Chairman of the UK’s National Advisory Committee for Aerospace
Manufacturing (NACAM)
T
he UK’s National Advisory Committee for Aerospace The normal production process is machining and material
Manufacturing (NACAM) is sponsored by the utilisation can be as low as 5%. But to ensure a sustainable
Department of Trade and Industry (DTI) through process for the manufacture of titanium alloy aerospace
the Aerospace and Defence Knowledge Transfer Network components, a step change in manufacturing process is
(KTN), reporting to the Aerospace Technology Steering required.
Group (ATSG) and the National Defence Industries Council ● Affordable composites
(NDIC) R&T committees. The purpose of the NACAM is to The increasing use of fibre reinforced polymer composites
advise UK Government on the future direction of aerospace provides a major potential competitive advantage in aircraft
manufacturing research and technology. development. However, several requirements must still be met
This includes: identifying long-term R&D needs in order to enable economic use, including new composite
and defining the priorities for aerospace and defence coatings, lower labour cost processes and new design,
manufacturing R&D through the generation of technology modelling, analysis and inspection tools.
roadmaps linked to technology readiness levels; identifying ● Ultra low-cost tooling
and prioritising aerospace manufacturing business The cost of tooling is a significant portion of the investment
opportunities and defence capabilities in particular those costs in an aerospace programme. In line with the development
leading to collaborative research actions; promoting of new manufacturing processes used within the aerospace
networking; identifying consortia to pursue collaborative sector, there is also a requirement to develop new tooling
projects; and stimulating new research proposals. solutions at reduced cost to remain competitive.
Comprising representatives from UK industry, academia, DTI, ● Digital manufacture
EPSRC and the Ministry of Defence, the NACAM has carried Many of today’s aerospace products are now controlled
out a review of the aerospace manufacturing R&D technologies by a digital thread, throughout design, manufacture and
through discussions, structured interviews and workshops with execution, which is becoming more accessible to aid aspects
industry, academia and research institutes. This review identified of manufacturing such as automation, facilities controls
around twenty major research themes of immediate importance, and inspection methods. Managing the digital thread in an
with six selected as priorities for more detailed evaluation and integrated way and maximising the opportunity offered by new
development through further workshops to identify and rank advanced processes and toolsets will result in true design for
the leading research topics for each theme and prepare detailed manufacture, reduced variation, increased quality, improved
road maps together with benchmarking and maturity levels. product / facility knowledge and increased repeatability, in
The six priority major research themes are: turn significantly reducing manufacturing costs and increasing
● Surface engineering and coatings competitiveness.
Engineering coatings are used extensively in the aerospace ● Assembly integration
sector. The driver for replacement of coatings is legislation The future assembly needs in the UK aerospace industry will
that will restrict their use on health, safety and environmental be very diverse, in both the civil and military sectors. Large
grounds. With composites, coating technologies are at a much or small civil aircraft, military jets, and unmanned air vehicles,
earlier maturity stage and the need for new coatings and all place unique demands upon assembly variation in rate, size
processes is more urgent. of airframe and engine, use of new materials, reduced fly-away
● Net shape titanium cost, and so on, are all driving factors.
Titanium alloys are increasingly used in aerospace structural The NACAM advises these themes should be considered
applications and projections are that demand will outstrip in future development strategies and calls for research for
availability, increasing procurement lead times and costs. aerospace manufacturing.
AM_jul07_p46_final.indd 46 29/6/07 17:07:39
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