Additionally, by integrating metrology data with the broader manufacturing ecosystem, aerospace manufacturers can become more predictive and reactive to the steps before and after their processes. These data will empower them to be more agile and responsive to fluctuations in supply and demand, ultimately enhancing their overall competitiveness.
Attracting and retaining skilled metrology professionals
By leveraging measurement data from the shop floor, manufacturers can create digital twins that closely mirror the actual production environment. For example, Hexagon’s Nexus platform facilitates collaborative engineering in a shared 3D environment. Using real-world measurement data, Nexus enables engineers to simulate various manufacturing processes, including CNC machining, metal forming, and welding. By continuously updating these digital twins with data from metrology equipment, manufacturers can optimize their processes, predict potential issues, and make informed decisions in real time.
To help bridge the gap between real-world and simulated environments, digital twins—or virtual replicas of physical assets—are gaining traction in the aerospace industry. Digital twins let manufacturers create highly accurate virtual models of their production processes, machines, and parts, enabling them to simulate and optimize various aspects of the manufacturing process.
Another significant challenge facing the aerospace industry is people—attracting and retaining skilled metrology professionals. The need for experts who can operate and maintain these sophisticated systems is growing ever stronger as the industry continues to adopt advanced technologies.
Equally important is the seamless integration of metrology solutions with the manufacturing ecosystem. Quality control data must flow seamlessly between metrology software, manufacturing execution systems (MES), and quality assurance platforms. By enabling real-time data exchange, this integration allows manufacturers to proactively identify and address quality issues, improving overall production efficiency. When connecting metrology equipment with the broader manufacturing landscape, aerospace companies can achieve a more holistic view of their processes, identifying opportunities for improvement.
The aerospace industry is undergoing significant changes in quality control and inspection, driven by advancements in metrology technologies and innovative manufacturing approaches. From automation and noncontact measurement to artificial intelligence and digital twins, these solutions empower manufacturers to enhance quality, improve efficiency, and reduce costs.
Using digital twins and simulated environments offers several benefits for aerospace manufacturers. First, it facilitates virtual testing and validation, allowing for earlier identification and rectification of issues in new designs and processes, ultimately saving time and resources by reducing reliance on physical prototypes. Second, it lets manufacturers identify potential problems and optimize processes before implementation, minimizing the risk of costly errors and rework. Finally, digital twins foster collaboration and knowledge sharing, empowering geographically dispersed teams to work together seamlessly and make data-driven decisions in real time.
Usability and integration: Keys to successful implementation
To address this, manufacturing leaders are adopting noncontact measurement technologies such as laser line and laser scanning combined with automation. These technologies facilitate faster, more accurate data capture that allows manufacturers to inspect parts more efficiently and identify potential issues early in production.
This will enable them to more quickly identify the source of problems (whether in the design, materials, or manufacturing processes), ultimately leading to more efficient problem-solving and continuous improvement.
Digital twins and simulated environments
In addition, AI-powered data analysis can provide valuable insights into process improvements and optimization opportunities. Manufacturers can gain a significant advantage by analyzing historical data and identifying trends. Doing so allows them to optimize process adjustments, predict tool wear, and proactively manage maintenance schedules, which minimizes downtime, improves product quality, and reduces costs. This data-driven approach means that aerospace manufacturers can continuously improve their processes, enhance product quality, and reduce waste.
Linking metrology to manufacturing operations
Additionally, investing in comprehensive training programs and ongoing support can help manufacturers build and maintain a skilled metrology workforce. When aerospace companies create an environment that fosters collaboration, innovation, and professional development, they can attract and retain the talent necessary to drive their quality control processes forward.
Shaping the future of aerospace quality control
Quality control and inspection play a critical role in the aerospace manufacturing process, ensuring that every component meets the most stringent safety and performance standards. However, traditional inspection methods can be time-consuming, labor-intensive, and prone to human error. To overcome these challenges and keep pace with the evolving needs of the aerospace sector, manufacturers are turning to advanced metrology solutions and innovative manufacturing approaches.
To successfully adopt these technologies, manufacturers must take a holistic approach encompassing technical aspects, human factors, and organizational considerations. Metrology solution providers like Hexagon can support this transition by developing user-friendly, integrated solutions for the manufacturing ecosystem.
To address this challenge, we must make metrology more appealing to the next generation of young professionals. We can achieve this by emphasizing the technology’s cutting-edge nature, continuous learning and growth opportunities, and the critical role that metrology plays in ensuring aircraft safety and performance.
Metrology data play a crucial role in facilitating this link. By making inspection data available for the next steps in the manufacturing process—and allowing for supply chain investigation—aerospace manufacturers can create a more integrated, responsive quality control system.
By learning from previous measurement runs, these intelligent systems can optimize data filtering and processing, reducing time by up to 50%. That translates to faster data processing, enabling manufacturers to pinpoint patterns and anomalies that could signal potential quality problems. The integration of AI in metrology allows for predictive quality control, where manufacturers can identify potential issues and address them before they escalate, minimizing scrap rates and reducing overall production costs.
Another critical challenge to aerospace quality control is linking metrology to manufacturing operations. By establishing a solid connection between these two domains, manufacturers can facilitate faster root cause analysis and issue correction when they arise.
At Hexagon, we’ve focused on developing user-friendly interfaces and preconfigured functions that simplify programming and operation. These features allow manufacturers to train their workforce quickly, allowing operators to adapt to new equipment easily. By providing intuitive software and hardware solutions, metrology providers can help aerospace manufacturers maximize the value of their investments and ensure a smooth transition to new technologies.
Metrology solution providers like Hexagon play a critical role in facilitating this integration by developing open, flexible platforms that can interface with a wide range of manufacturing systems. By working closely with aerospace manufacturers to understand their unique requirements and existing infrastructure, metrology providers can develop customized solutions that seamlessly integrate with the existing ecosystem, creating a more streamlined, efficient quality control process.
As the aerospace industry continues to evolve, integrating advanced metrology technologies will be instrumental in producing safer, more efficient, and sustainable aircraft. By embracing these solutions, the aerospace community can ensure that quality, safety, and innovation remain at the fore of this critical sector.