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ZAero SIGNED

Zero-defect manufacturing of composite parts in the aerospace industry

Total Cost €

EC-Contrib. €

Partnership

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Outcomes and
results

ZAero project word cloud

Explore the words cloud of the ZAero project. It provides you a very rough idea of what is the project "ZAero" about.

eacute causing human danobat group fibre assessing defective line decision mtorres fidamc consists syst covers wing dassault verification savings assist re losses carbon extended met tools combination logistical inspection planes standards inline planning hundred thousand quality solved visual huge airbus a320neo dry assuming bottleneck concerned industry material manufacturing flow stage automatic play aerospace deal 2025 curing euros 30 players situ 50 defects mes meur rates productivity cover placement lay 150 solution simulation builders machine innovations centers parts background

Project "ZAero" data sheet

The following table provides information about the project.

Coordinator	PROFACTOR GMBH Organization address address: IM STADTGUT A2 city: STEYR GLEINK postcode: 4407 website: www.profactor.at contact info title: n.a. name: n.a. surname: n.a. function: n.a. email: n.a. telephone: n.a. fax: n.a.
Coordinator Country	Austria [AT]
Project website	http://www.zaero-project.eu
Total cost	4˙124˙143 €
EC max contribution	3˙548˙206 € (86%)
Programme	1. H2020-EU.2.1.5.1. (Technologies for Factories of the Future)
Code Call	H2020-FOF-2016
Funding Scheme	IA
Starting year	2016
Duration (year-month-day)	from 2016-10-01 to 2019-09-30

Partnership

Take a look of project's partnership.

#	participants	country	role	EC contrib. [€]
1	PROFACTOR GMBH PROFACTOR GMBH Organization address address: IM STADTGUT A2 city: STEYR GLEINK postcode: 4407 website: www.profactor.at contact info title: n.a. name: n.a. surname: n.a. function: n.a. email: n.a. telephone: n.a. fax: n.a.	AT (STEYR GLEINK)	coordinator	927˙413.00
2	FUNDACION PARA LA INVESTIGACION, DESARROLLO Y APLICACION DE MATERIALES COMPUESTOS FUNDACION PARA LA INVESTIGACION, DESARROLLO Y APLICACION DE MATERIALES COMPUESTOS Organization address address: Avda Rita Levi Montalcini (Tecnogetafe) 29 city: Getafe postcode: 28906 website: www.fidamc.es contact info title: n.a. name: n.a. surname: n.a. function: n.a. email: n.a. telephone: n.a. fax: n.a.	ES (Getafe)	participant	665˙687.00
3	IDEKO S COOP IDEKO S COOP Organization address address: CALLE ARRIAGA 2 city: ELGOIBAR postcode: 20870 website: www.ideko.es contact info title: n.a. name: n.a. surname: n.a. function: n.a. email: n.a. telephone: n.a. fax: n.a.	ES (ELGOIBAR)	participant	611˙250.00
4	DASSAULT SYSTEMES DASSAULT SYSTEMES Organization address address: RUE MARCEL DASSAULT 10 city: VELIZY VILLACOUBLAY postcode: 78140 website: www.3ds.com contact info title: n.a. name: n.a. surname: n.a. function: n.a. email: n.a. telephone: n.a. fax: n.a.	FR (VELIZY VILLACOUBLAY)	participant	447˙125.00
5	AIRBUS DEFENCE AND SPACE GMBH AIRBUS DEFENCE AND SPACE GMBH Organization address address: WILLY-MESSERSCHMITT-STRASSE 1 city: TAUFKIRCHEN postcode: 82024 website: www.airbus-group.com contact info title: n.a. name: n.a. surname: n.a. function: n.a. email: n.a. telephone: n.a. fax: n.a.	DE (TAUFKIRCHEN)	participant	365˙498.00
6	M TORRES DISEÑOS INDUSTRIALES SA M TORRES DISEÑOS INDUSTRIALES SA Organization address address: CTRA. PAMPLONA-HUESCA, KM.9 city: TORRES DE ELORZ postcode: 31119 website: www.mtorres.es contact info title: n.a. name: n.a. surname: n.a. function: n.a. email: n.a. telephone: n.a. fax: n.a.	ES (TORRES DE ELORZ)	participant	315˙980.00
7	DANOBAT DANOBAT Organization address address: POLIGONO INDUSTRIAL ARRIAGA 21 city: ELGOIBAR postcode: 20870 website: www.danobat.com contact info title: n.a. name: n.a. surname: n.a. function: n.a. email: n.a. telephone: n.a. fax: n.a.	ES (ELGOIBAR)	participant	215˙250.00

Map

Project objective

In the aerospace industry very high quality standards have to be met. For the manufacturing of carbon fibre parts this is currently solved through extended end-of-line inspection in combination with re-work processes to deal with defective parts. Also, in-situ visual inspection is used for quality control, which is currently causing huge productivity losses (30%-50%) during lay-up and has become a real bottleneck in carbon fibre parts manufacturing.

The project will provide a solution by developing inline quality control methods for the key process steps: automatic lay-up (dry fibre placement and automatic dry material placement) and curing. At the system level decision support systems will be developed that assist human decision-making when assessing defects and when planning the part flow through the production line. These will be supported by simulation tools for part verification and logistical planning. The future manufacturing of the A320neo wing covers will be provide the background for the developments. Each such wing cover consists of two parts, that each cost several hundred thousand Euros in manufacturing. Assuming the planned production rates of 60 planes per month from 2025, savings of 150 MEUR in production costs can be obtained per year.

The consortium consists of all key players that will play a future role in the manufacturing of such large carbon fibre parts. Airbus with its research centers Airbus Group Innovations and FIDAMC will play a leading role in the consortium as far as the multi-stage manufacturing process is concerned. Machine builders (MTorres, Danobat) and research centers will develop the inline quality control, while Dassault Systémes will provide simulation support.

Deliverables

List of deliverables.
\"Demonstration #3 and evaluation report\"	Demonstrators, pilots, prototypes	2020-04-23 23:57:29
\"Demonstration #2 and evaluation report\"	Demonstrators, pilots, prototypes	2020-04-23 23:57:29
Project web page	Websites, patent fillings, videos etc.	2020-04-23 23:57:28
Data Management Plan	Documents, reports	2020-04-23 23:57:28
\"Demonstration #1 and evaluation report\"	Demonstrators, pilots, prototypes	2020-04-23 23:57:28

Take a look to the deliverables list in detail: detailed list of ZAero deliverables.

Publications

List of publications.
year	authors and title	journal	last update
2019	Robert Steringer, Helmut ZÃ¶rrer, Sebastian Zambal, Christian Eitzinger Using Discrete Event Simulation in multiple System Life Cycles to support Zero-Defect Composite Manufacturing in Aerospace Industry published pages: , ISSN: , DOI:	9th IFAC Conference on Manufacturing Modeling, Management, and Control August 2019	2020-04-23
2019	Pierre-Yves Mechin; Michael Clarke CaractÃ©risation de l\'incidence des dÃ©fauts de manufacturing robot sur la rÃ©sistance des composites Carbone-Epoxy haute performance dans l\'aÃ©ronautique published pages: , ISSN: , DOI: 10.5281/zenodo.3354217	21Ã¨me JounÃ©es Nationales sur les Composites(JNC) 1-3 July, 2019	2020-04-23
2019	Christian Eitzinger; Paulo Leitao; Salvador Izquierdo Estallo Innovative Technologies and Methods for Zero Defect Manufacturing on Industrial Cyber-Physical Systems Context published pages: , ISSN: , DOI: 10.5281/zenodo.3354144	INDIN 2019 Call for papers: Innovative Technologies and Methods for Zero Defect Manufacturing on Industrial Cyber-Physical Systems Context 2	2020-04-23
2018	Celine Le Gleuher, Christopher Buchmann, Katharina Schlegel, Alois Friedberger Advanced flow front and cure monitoring using high frequency technology published pages: , ISSN: , DOI: 10.5281/zenodo.3354175	Conference of the Society for the Advancement of Material and Process Engineering (SAMPE) September 2018	2020-04-23
2019	Helmut ZÃ¶rrer, Robert Steringer, Sebastian Zambal, Christian Eitzinger Using Business Analytics for Decision Support in Zero Defect Manufacturing of Composite Parts in the Aerospace Industry published pages: , ISSN: , DOI:	9th IFAC Conference on Manufacturing Modeling, Management, and Control August 2019	2020-04-23
2018	Sebastian Zambal, Christian Eitzinger, Michael Clarke, John Klintworth, Pierre-Yves Mechin A digital twin for composite parts manufacturing published pages: , ISSN: , DOI:	Conference on Industrial Informatics (INDIN) 18th - 20th of July 2018	2020-04-23
2019	S. Zambal, C. Heindl, C. Eitzinger Machine Learning for CFRP Quality Control published pages: , ISSN: , DOI:	Conference of the Society for the Advancement of Material and Process Engineering (SAMPE) September 2019	2020-04-23
2018	Christian Eitzinger, Sebastian Zambal Inline Inspection Technologies for Processing of Dry Fibre Materials published pages: , ISSN: , DOI:	Conference of the Society for the Advancement of Material and Process Engineering (SAMPE) 11th-13th September 2018	2020-04-23
2017	Rodriguez, Ana Rosa; Cuenca, Jose; Ruiz, Rocio; Calero, Alvaro ZAero - Zero defect manufacturing of composite parts in the aerospace industry published pages: , ISSN: , DOI:	ZENODO 1	2020-04-23
2019	S. Zambal, C. Heindl, C. Eitzinger, J. Scharinger End-to-End Defect Detection in Automated Fiber Placement Based on Artifcially Generated Data(How can we use deep learning for quality control with little data?) published pages: , ISSN: , DOI:	International Conference on Quality Control by Artificial Vision, Mulhouse, France, 2019 May 15, 2019	2020-04-23
2018	Ana Rosa Rodriguez, Jose Cuenca, Rocio Ruiz, Alvaro Calero ZAero- Cero Defectos en la fabricaciÃ³n de piezas de material compuesto en la industria aeroespacial published pages: 128 - 131, ISSN: , DOI: 10.5281/zenodo.1247421	Materiales Compuestos vol 2, no 2, 2017	2020-04-23

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The information about "ZAERO" are provided by the European Opendata Portal: CORDIS opendata.