Case Study: Eclipse Tooling

The aircraft industry has always suffered from production constraints imposed on them due to the relatively low production volumes. The traditional high cost associated with press tooling forming is often not a viable production process and for this reason aircraft manufactures have turned to hydro-form, sometimes referred to as flex-form or fluid cell press.

This process makes use of a low cost one piece tool, on which sheet metal is formed using the application of high pressure oil (typical between 300-1000bar) applied via a rubber bladder.

The use of knowledgeware
Intrinsys were commissioned to design a large quantity of flex form tools, the traditional approach would have been to assign a large number of engineers to the task.

Instead, the Intrinsys approach was to generate a CATIA Knowledge Based Template, which would be used to automate the creation task. This was achieved by adding design rules and parameters into the CATIA model, which allowed a new model to be instantiated into the template and then updated so that the knowledge based rules were then applied.  The result was a process to create the tooling models and associated cutter paths in an automated manner with only minimal user input.

This approach provided a number of customer benefits:

  • Reduce design lead-times
  • Enforces the application of best practise and quality to be maintained  across the aircraft tooling
  • Enables any lessons learned during the development process to be easily incorporated into future designs
  • Reduce engineering costs including  design and CNC manufacture

This approach was highly successful in meeting the customer aggressive timescale.