As manufacturers in the aerospace sector, we at Bertrand Products are more than a little obsessive over the details. When it comes to making parts, we live and breathe the intricacies of aerospace design. We need to, and we love to. See, to us, it’s so much more than lines on a screen. Aerospace design is the fundamental driver behind every single part. So, it influences everything from the concept to its installation on a helicopter.
When it comes to aerospace manufacturing, we rely on design. It’s the bedrock of the entire workflow, from tooling up to final procurement. So, if you want to know more about aerospace design, you’re in the right place. Let’s take a look!
Core Principles: Building from the Ground Up
When we talk about aerospace design, there are three non-negotiables:
- Durability
- Efficiency
- Safety
These are the driving forces behind every part we make. If anything goes wrong, it would lead to catastrophe. We cannot accept that.
The Role of Aerospace Design in Product Lifecycle Management
From design to deployment, aerospace design plays a role throughout the product’s lifecycle.
Right from the beginning with the design phase, every decision affects the entire process. So, let’s look at the major steps of the process:
Compliance Standards
If you work in any regulated sector, you know how important those standards are for your work. Aerospace perhaps most of all!
Those standards and regulations are a key part of the process. They are the blueprint for the precision we need to achieve. If that part isn’t perfect, it’s not going into the air. Key certifications and standards include:
- ISO: A set of international standards ensuring quality management systems, processes, and services meet customer and regulatory requirements.
- MIL-spec (Military Specifications): Standards developed to define military product requirements, ensuring uniformity, interoperability, and performance for defense-related applications.
- AS9100D: The aerospace industry’s quality management standard for aviation, space, and defense. It covers system and component design, development, production, installation, and servicing.
- NADCAP (National Aerospace and Defense Contractors Accreditation Program): A global cooperative accreditation program for aerospace engineering, defense, and related industries. Establishes requirements for suppliers to meet in manufacturing processes, like heat treating, welding, and non-destructive testing.
Design Technologies
So, how do we make sure we design perfect parts that meet these regulations? It’s all about technology. Software tools have become mainstays for designing and creating all kinds of parts, whether they are on the ground or in the air. Prime examples include:
- Computer-Aided Design (CAD): Creates detailed 3D models and engineering drawings.
- Computer-Aided Manufacturing (CAM): Bridges the gap from the CAD to the CNC machine. So, the intended design is what we make on the shop floor.
- Computer-Aided Engineering (CAE): Performs simulations and analyses. We can predict performance, stress, and fatigue before we make a single cut.
These tools have become vital for enhancing functionality and cost-efficiency in modern aerospace design and production.
Choosing Materials
When it comes to aerospace parts, the material is an engineering decision. Whether we’re working with aluminum, titanium, or composites, each material brings its own set of properties to the table. So, we must take these properties into account and work within them to design the optimal part.
Production
Recent advancements in aerospace design are impacting production, as well. These innovations streamline manufacturing processes directly through design.
For instance, generative design allows for optimized, lighter, and stronger parts. These often require creative manufacturing techniques.
Even if additive manufacturing (3D printing) hasn’t quite matched what we expected it to do in years past, it is still useful for design.
Similarly, designs optimized for automated composites manufacturing enable faster, more repeatable production.
Deployment
We all know the challenges inherent in deployment. We are counting every gram and testing every stress. These are the real-world constraints that push us to innovate our design solutions. It’s in tackling these hurdles that aerospace design truly shines, finding new, creative ways to make sure the system can fly safely and efficiently.
From Concept to Component: The Art of Realization
Ultimately, the brilliance of aerospace design isn’t in the theoretical, but in the execution of the design and its performance. Every choice, from the first sketch to the final spec, directly impacts the helicopter’s ability take and maintain flight.
As precision manufacturers, we’re the ones who bridge that gap, bringing those complex designs to life.
Have you encountered specific design challenges in your manufacturing processes? Or perhaps you have questions about how material properties translate into real-world performance? We’re always keen to discuss the blueprint. Reach out to Bertrand Products and find out more about how we can help your dreams take flight!
