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Robotic Machining Cell for Composite Aero-Structures
IDEKO and aerospace manufacturers demonstrate high-precision robotic machining and inspection of composite wing components at BIEMH 2026 to advance industrial automation in aerostructure production.
www.ideko.es
Composite aero-structures made from carbon fibre reinforced polymers require tight tolerances during drilling and milling operations. IDEKO has developed and validated a high-precision robotic cell that integrates machining and inspection processes to address positioning accuracy and process stability limitations typical of standard industrial robots.
Context of the Cooperation
IDEKO, a member of the Basque Research and Technology Alliance, collaborates with aerospace manufacturers to transfer advanced manufacturing technologies from applied R&D to industrial environments. The cooperation focuses on machining large composite components such as wing structures, where dimensional tolerances, hole quality, and surface integrity directly affect assembly accuracy and structural performance.
Conventional articulated robots offer flexibility and large working envelopes but lack the structural stiffness and volumetric accuracy of precision machine tools. For composite materials, additional constraints arise from delamination risk, fibre pull-out, and dust emissions during drilling and trimming. Addressing these challenges requires combined expertise in robotics, metrology, fixture design, and process engineering.
Technical Solution and Responsibilities
IDEKO has designed an intelligent robotic cell integrating milling, drilling, deburring, and in-process inspection. The system combines:
- Photogrammetric measurement and computer vision to continuously track the robot end-effector over large volumes.
- Real-time position correction using predictive metrological models.
- Automatic camera repositioning along the machining trajectory.
- Automatic component referencing once the part is clamped.
- Adaptive toolpath generation based on measured geometry.
This architecture reduces positioning errors during machining and improves repeatability without extensive manual recalibration. Advanced sensing systems monitor vibrations and process parameters, enabling early detection of instability that could affect surface quality or hole integrity.
To mitigate composite-specific defects, machining strategies are optimized to reduce delamination. Integrated extraction systems capture carbon fibre dust at source, improving workplace safety and compliance with occupational exposure requirements.
IDEKO is responsible for system architecture, metrology integration, fixture design, and commissioning. Industrial partners contribute representative aero-structure components, operational requirements, and validation under production-like conditions.
Deployment and Integration
The demonstrator, presented at BIEMH 2026 in Bilbao, applies the cell to a representative aircraft wing component. The cell architecture considers:
To mitigate composite-specific defects, machining strategies are optimized to reduce delamination. Integrated extraction systems capture carbon fibre dust at source, improving workplace safety and compliance with occupational exposure requirements.
IDEKO is responsible for system architecture, metrology integration, fixture design, and commissioning. Industrial partners contribute representative aero-structure components, operational requirements, and validation under production-like conditions.
Deployment and Integration
The demonstrator, presented at BIEMH 2026 in Bilbao, applies the cell to a representative aircraft wing component. The cell architecture considers:
- Accessibility of the robot and machining head to all functional areas.
- Control of gravity-induced deformation.
- Compatibility with digital referencing systems.
- Positioning repeatability under machining loads.
Custom fixtures ensure stable clamping while allowing automatic referencing and geometry-based path correction. The system integrates into existing digital infrastructure, enabling data collection for process optimization and traceability.
Applications and Expected Impact
The solution targets aerospace aerostructure manufacturing, particularly large composite components. Use cases include precision drilling for assembly interfaces, trimming operations, and in-line dimensional verification.
Rather than replacing machine tools, the approach extends industrial automation into applications requiring higher volumetric accuracy. By combining real-time metrology, adaptive control, and optimized fixturing, the cell improves process stability, reduces manual intervention, enhances surface quality, and supports safer machining of carbon fibre materials.
www.ideko.es
Applications and Expected Impact
The solution targets aerospace aerostructure manufacturing, particularly large composite components. Use cases include precision drilling for assembly interfaces, trimming operations, and in-line dimensional verification.
Rather than replacing machine tools, the approach extends industrial automation into applications requiring higher volumetric accuracy. By combining real-time metrology, adaptive control, and optimized fixturing, the cell improves process stability, reduces manual intervention, enhances surface quality, and supports safer machining of carbon fibre materials.
www.ideko.es
