CASE STUDIES
FLEXCELLE
ELCAT | MADE SMARTER | ELASTIC | ASTRAL | VADIS | WINGLIFT | AUTORAMP | SMARTER | CASE STUDIES
FLEXIBLE NACELLE MANUFACTURING
The FLEXCELLE project set out to reimagine the assembly of aerostructures by applying Measurement Assisted Determinate Assembly (MADA) and digital manufacturing technologies to the assembly of fuselage structures.
Running from June 2019 to August 2023, the project aimed to demonstrate that jig-less assembly methods could provide a faster, more flexible and cost-effective alternative to traditional aerospace manufacturing approaches.
The project brought together leading industry partners including Safran, BAE Systems, Spirit AeroSystems, Toolroom Technology Limited, the Advanced Manufacturing Research Centre and the University of Nottingham. Assembly activities were carried out at the Omnifactory facility, showcasing advanced metrology and digital manufacturing integration in a live industrial environment.
Traditional aerostructure assembly methods are time consuming, costly and inflexible, relying heavily on large, fixed tooling and infrastructure that limits adaptability to design or production changes.
FLEXCELLE addressed these challenges by developing and validating MADA-based manufacturing techniques, which use integrated metrology and automation to eliminate the need for conventional jigs. This approach dramatically reduces non-recurring cost (NRC) investment and accelerates production ramp-up times.
Digital manufacturing tools and data-driven processes were used to shorten development cycles and enable engineers to make informed decisions more quickly, improving both efficiency and responsiveness to market demand.
Within the University of Nottingham, contributions focused on:
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Development and validation of new assembly philosophies
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Demonstration of digital manufacturing tools to reduce time and cost
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Development of non-contact inspection routines and virtual commissioning
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Demonstration of fuselage assembly using MADA techniques
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Validation of MADA’s potential for full-scale fuselage assembly
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The project demonstrated, for the first time, that large-scale fuselage structures can be assembled using MADA processes, proving that jig-less assembly is a practical and precise alternative.
A key innovation was the ability to automatically inspect large-volume, reorientable products to validate the “as-built” condition. Traditionally, aerospace inspection required components to remain static, increasing inspection time and limiting accuracy. FLEXCELLE’s approach provided more complete inspection data in less time, giving manufacturers better insight and control during production.
The results achieved at Omnifactory showed:
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Over 50% reduction in non-recurring costs compared with conventional techniques
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Reduced production ramp-up times for new aircraft products
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Improved inspection accuracy through integrated digital metrology
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Faster decision-making for engineers through connected data flows
The University of Nottingham’s success in delivering this work led to new independent research projects with BAE Systems and Spirit AeroSystems.
The project was also highlighted in the Robotics and Automation Awards 2023, where the University of Nottingham was highly commended in the Innovation in Aerospace category, placing second to Airbus.
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The output of FLEXCELLE is considered game-changing for the aerospace sector. By proving the feasibility of MADA-based jig-less assembly, the project has created a new pathway for reducing the cost, time and environmental impact of aircraft production.
The FLEXCELLE approach delivers clear strategic advantages:
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Cost efficiency: Dramatically lowers capital investment and reduces NRC by up to 50 percent
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Time savings: Enables faster product ramp-up and more agile manufacturing responses
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Sustainability: Reduces material waste and energy use by reusing flexible tooling
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Quality assurance: Integrates digital inspection for precision assembly and data traceability
The project’s early industrial demonstrators have already had measurable impact. BAE Systems and Spirit AeroSystems are applying the results in new aircraft assembly line concepts.
Long-term, FLEXCELLE will continue to influence the future of adaptable aerospace manufacturing, supported by further research and exploitation activities through the University of Nottingham’s Institute for Advanced Manufacturing (IfAM).
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FLEXCELLE provides a strong foundation for the UK’s leadership in digital and reconfigurable aerospace manufacturing. The technologies and methodologies developed through this project will be central to achieving future sustainable, high-rate aircraft production, aligning closely with the ambitions of Made Smarter Innovation and the UK’s Aerospace Technology Strategy.
By combining digital engineering, metrology and automation, FLEXCELLE proves that intelligent, flexible assembly can deliver measurable improvements in cost, speed and environmental performance, setting a new benchmark for future aerostructure production.
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