AEROSUD
New Heights in Aircraft Component Manufacturing
AEROSUD
New Heights in Aircraft Component Manufacturing PRODUCTION: Eleanor Sarbutt-King
“It all starts with a passion,” beams renowned supplier of aerostructure and aircraft interior components, Aerosud, where the unique combination an expert engineering team and the in-house availability of the pinnacle of multiple manufacturing technologies allows the most complex industrialisation projects to be executed at breakneck speed.
//
Harnessing the wealth of expertise boasted by its 500 employees and the collective know-how garnered over a more than 30-year history, Aerosud’s aerostructure and aircraft components are trusted by some of the true giants of the industry. “Aerosud is well known to be the Swiss Army knife of extended manufacturing capability, and always supportive of emergent customer requirements in industrialising new
2 / www.enterprise-africa.net
products,” says Pilatus Aircraft, a viewpoint shared by Airbus Defence & Space: “Aerosud is technically agile in specialised manufacturing solutions; it is our manufacturing partner for the long-term offering innovative technology-driven solutions.” MULTIFACETED MANUFACTURE Such lofty billing does not come by accident, of course; it is earned only through rigorous processes,
a peerless project portfolio and a policy of continuous development and improvement. Aerosud’s metallic fabrication covers the full spectrum from traditional hand-formed parts to complex pressformed parts. “All associated tooling is designed in-house,” the company furthers, “with the design process making use of simulation software to ensure it is right first time. “Our supply chain network
INDUSTRY FOCUS: MANUFACTURING
includes a large number of South African-based tooling manufacturers.” In-house capability includes 3-axis and 5-axis machining and our wellestablished local network of world class machining suppliers includes the capability to machine hard metals. “We also manufacture simple as well as complex geometry parts,” Aerosud
4 / www.enterprise-africa.net
says, “using materials ranging from polycarbonates to Continuous Fibre Reinforced Thermoplastics (CFRTP). “Our in-house capability allows us to manufacture CFRTP parts up to 1m x 2m in size.” On the composite manufacturing side, Aerosud’s competences include both oven and autoclave cured parts
with an on-site autoclave enabling the manufacture of parts up to a diameter of 1.5 metres and length of three metres. “We complement our traditional composite manufacturing know-how with our patented technology, known as Cellular Core Technology (CCT),” explains Aerosud. “This unique manufacturing process results in significant weight and cost reductions. “Our composite facility includes a material testing laboratory where we are able to perform chemical analysis, thermal analysis, thermo-mechanical testing as well as mechanical testing at elevated temperatures.” Expertise and OEM approvals in various joining technologies, such as adhesive bonding and riveting and fastening, means that Aerosud is able to manufacture complex assemblies from detailed parts, while robotic welding cells provide significant capacity to absorb production rate increases.
AEROSUD
INSURANCE SOLUTION SPECIALISTS
FOR ALL YOUR INSURANCE NEEDS GIB Insurance Brokers is structured to deliver the best, most effective business insurance and risk solutions to clients across South Africa and the African continent. We have created a diverse mix of complementary businesses, each run by teams who are experts in their fields and together have grown GIB to be the largest independently owned insurance broker in the country. GIB is a proud Level 1 B-BBEE contributor.
AVIATION | COMMERCIAL | CORPORATE | FILM AND ENTERTAINMENT | MARINE MINING | PERSONAL | PROPERTY AND PROFESSIONS | RENEWABLE ENERGY | RISK SOLUTIONS
+27 11 483 1212 | info@gib.co.za | www.gib.co.za FSP 10406
NEW TECHNOLOGIES “We are built on passion,” Aerosud summarises. “We take that passion and develop it, with more than 600 pairs of hands building aircraft parts and more than 600 voices communicating daily. We are an African solution, focusing on partnerships and collaboration.” In order to remain the first-choice African provider, as well as to ensure the continuous provision of a competitive total cost of business in the global aerospace market, Aerosud has in recent years consistently invested in the development of multiple technology streams, including those connected to Industry 4.0. One particular development, a patented technology known as cellular core technology (CCT), paves the way for the manufacture of highly complex assemblies in one single piece; the result is significant reductions in part
count as well as assembly time, which in turn reduces overall cost and weight. Traditionally, assembly of aircraft structures is complex and comprises costly machined metallic parts that are fastened together using large quantities of metallic fasteners, labour intensive assembly methods as well as expensive assembly jigs. The contemporary requirement for lighter and, therefore, fuel-efficient structures, has led to a significant increase in the use of composite materials in the latest generation aircraft structures. “For Aerosud to remain a relevant supplier in the aerostructures supply chain, we have over the past number of years invested in a unique manufacturing and tooling technology specifically developed for structural composite parts,” the company responds. “The uniqueness of CCT is in
the tooling methodology used for manufacture of the part. To date, CCT has demonstrated the ability to achieve a reduction in part count of up to 75% together with a weight reduction exceeding 20%. Customers have reported on an estimated cost reduction of up to 30%,” Aerosud sums up, with its forward-thinking ethos and renowned nurturing and support of industry talent set to keep it soaring long into the future.
WWW.AEROSUD.CO.ZA
www.enterprise-africa.net / 5
CMB Media Group does not accept responsibility for omissions or errors. The points of view expressed in articles by attributing writers and/ or in advertisements included in this magazine do not necessarily represent those of the publisher. Any resemblance to real persons, living or dead is purely coincidental. Whilst every effort is made to ensure the accuracy of the information contained within this magazine, no legal responsibility will be accepted by the publishers for loss arising from use of information published. All rights reserved. No part of this publication may be reproduced or stored in a retrievable system or transmitted in any form or by any means without the prior written consent of the publisher. © CMB Media Group Ltd 2024
THE BUSINESS MAGAZINE FOR AFRICA’S INDUSTRY LEADERS
AFRICA
Published by CMB Media Group Chris Bolderstone – General Manager chris@cmb-media.co.uk Kiln House, Fuel Studios, Pottergate, Norwich NR2 1DX T. +44 (0) 20 3097 1743 E. info@cmb-media.co.uk www.cmb-media.co.uk
January 2024
www.enterprise-africa.net
Mission-Driven KZN Oils Upholds Lasting Legacy Exclusive interview with KZN Oils CEO, Esay Reddy ALSO IN THIS ISSUE:
Exxaro / Macsteel / South African Breweries / Aerosud
A S F E AT U R E D I N
ENTERPRISE AFRICA JA N U A RY 2024