Innovative Tooling Solutions for Aircraft Assembly: A Case Study on the Development of Reconfigurable and Lightweight Fixtures

This paper presents a case study on the development of reconfigurable and lightweight fixtures for aircraft assembly, which are essential for modernizing and automating tooling fixtures in the aeronautical industry. Our study utilizes generative engineering and other design techniques to optimize performance and meet design objectives. Generative engineering combines parametric and algorithmic design with mathematical optimization, while generative design utilizes algorithmic methods to generate feasible designs based on performance goals, constraints, and design space. To determine the most appropriate optimization tools, we conducted a thorough study of available options and selected the most suitable ones based on available resources. Our newly developed fixtures are flexible and adaptable to various types of aircraft structures, including fuselages and wings, and meet crucial vibration requirements for aircraft assembly operations such as drilling and riveting. The new fixtures are also lightweight and easier to handle, contributing to a reduction in development costs and enhancing production efficiency. This contribution can help to enhance the competitiveness of the Basque aeronautical industry and position it as a key player in the global aviation market. The findings of this study demonstrate the benefits of incorporating generative engineering and novel design techniques into the development of innovative tooling solutions for aircraft assembly.