Augment manual composites manufacturing with digital technologies
In-process training and inspection to support consistent layup and reduce scrappage.
A new solution addresses one of the biggest challenges in manual composites manufacturing: consistency. Layup of complex 3D structures relies heavily on skilled, manual processes that require dexterity and decision-making. Variance is high and training new technicians takes time.
A new solution has been developed that enables dexterous manufacturing, supports new and experienced technicians, and enhances composite production.
NCC is seeking partners to develop immersive workbench technology and create a commercially available product for manufacturers.
The problem
Composite materials are used across a wide range of high-growth industries, including aerospace, wind energy, marine, and automotive. Composites are often built up layer-by-layer, and while automated solutions exists, creating parts with complex geometries relies on manual 'hand layup'.
Re-work and scrappage can be high for composite processes, so part manufacturing relies on a finite number of highly skilled technicians. Training new technicians to the same standard takes time, while variance are still seen across different teams and sites.
The industry needs solutions which introduce consistency to composite processes, reduce reliance on experienced individuals, and train new technicians faster.
The solution
Created by NCC, Immersive Workbench Technology is a digital assistance system designed to support manual composite layup operations.
It transforms a traditional workbench into an interactive workspace, combining digital instructions, multimedia guidance, and projected ply outlines directly onto the tool surface. The result is a more intuitive and engaging way for operators to perform complex layup tasks.
Key benefits:
- Reduction in training needs for composite laminators, overcoming the upskilling resource issue.
- Faster, resource efficient final inspection for composite production, reducing time on manual checking.
- Improved product development within composites, with consistent quality in output.
- Supporting composite manufacturers to reduce waste, saving the manufacturer costs.
- Documentation of manual manufacturing processes for digital passport creation
Application
The technology can help with manual lay up of composites across a wide range of industries – from aerospace, to sustainable energy such as wind energy, marine environments, and oil and gas – reducing training needs, and improving composite product development.
A 'Digital thread' enables model-based systems engineering, meaningful AI integration, and more efficient product development.
But the challenge for composites is that manufacturing is often dependent on manual processes that are difficult to capture digitally.
Immersive Workbench Technology bridges the gap between manual processes and digital tools.