New Technology and Capability Development Enables Multi-billion Dollar Aircraft Component Program

Problem:

Hawker de Havilland (HdH), now Boeing Aerostructures Australia, was a Tier 2 supplier of composite aircraft components to Boeing. It was traditionally a facility using conventional prepreg hand lay-up and autoclave curing procedures. Its ambition was to become a Tier 1 supplier (i.e. design, analyse and build).

Approach:

CRC-ACS established R&D offices and workshops within HdH sites. It seconded HdH staff to work alongside ACS Australia personnel, undertaking research projects as part of a program to address the long-term needs of HdH. Together they developed technologies so that HdH was in a position to bid for future aircraft programs with new technology.

Solution:

The CRC-ACS research program introduced and transferred to HdH the main new technologies used to design, analyse and manufacture a range of advanced composite components. These technologies included resin infusion, diaphragm forming, process simulation, post-buckling analysis, bird strike simulation and design optimisation. ACS Australia personnel worked at the HdH sites to facilitate the implementation.

Outcome:

HdH leveraged advanced composites technologies developed within CRC-ACS to be awarded the responsibility to construct all the Wing Trailing Edge Devices, including flaps, spoilers and ailerons, on the new Boeing 787 program. The entire 787 program is expected to generate at least AUD 4 billion in exports over its lifetime. The programme developed world-class composites technologies, giving HdH a competitive advantage and providing HdH with confidence to bid beyond their existing capability level. HdH realised their ambition to become a “Tier 1” supplier and staff competency was enhanced.