Modular tooling process for airframe structures

Edited by the Engineeringtalk editorial team Feb 23, 2001

Boldman has been granted exclusive worldwide rights by BAE Systems to license their patent pending modular tooling process, used to manufacture major airframe structures.

Boldman has been granted exclusive worldwide rights by BAE Systems to license their patent pending modular tooling process, used to manufacture major airframe structures.

Boldman has worked closely with BAE Systems during the last three years of the development stage of the process and as a result, was awarded with the first modular tooling contract in the World.

The contract consisted of eleven structures for the production of Eurofighter fin and rudder assemblies.

These structures have now entered Eurofighter production with savings of over 40% compared to conventional tooling costs.

The BAE Systems element of the Joint Strike Fighter programme has benefited significantly from the modular tooling process, with the majority of ground based demonstrator assemblies being manufactured in nine modular structures.

Some of these structures are now based at the Lockheed Fortworth facility in Texas.

There are also two modular tooling structures to be found at Northrop Grumman facility in California and where used to deliver Northrop's JSF development programme requirement.

Both structures where exported directly to Northrop by Boldman.

The patent pending process in which Boldman Ltd is a named contributor, uses Boldman standard "off the shelf" catalogue parts that are mass produced and consist of aluminium profiles, modular pickups and accessories.

The assembly of which is supported by laser tracker technology and appropriated assembly software.

The savings attributed to this revolutionary new process are born from an "end to end" development approach that has examined every aspect of conventional assembly tooling from design through to manufacture and assembly.

The modular process fully exploits investment in CAD technology, greatly reducing costs associated with design, drafting, manufacture and assembly.

Estimating is made simple through the use of standard parts.

Lead times are typically 4 to 6 weeks for frame structures and pickups.

As well as providing the customer with a capable structure, modular tooling offers the benefits of being fully adjustable and re-configurable, enabling design changes or errors to be incorporated at any stage of the manufacturing or assembly process.

Whilst to date the majority of modular assembly tools have been in support of the aerospace industry, this technology has the potential to deliver major benefits across a diverse range of industries.

Boldman is now the leading supplier of aluminium modular tooling to the aerospace industry in the UK.

They are also a leading supplier to UK industry in the supply of machine building aluminium profiles and accessories and is addressing the industrial capital goods market, within which it is now starting to create a niche for its expertise.

The versatility of the product has created massive opportunities in a wide variety of industries, from aerospace, food, pharmaceuticals, research, electronic, colleges, universities, motor sport and automotive to name a few.