CASE STUDIES
VADIS
ELCAT | FLEXCELLE | MADE SMARTER | ELASTIC | ASTRAL | WINGLIFT | AUTORAMP | SMARTER | CASE STUDIES
VARIANCE AWARE DETERMINATE ASSEMBLY INTEGRATED SYSTEM
The VADIS project aimed to develop innovative and cost-effective wing assembly methods for the next generation of regional aircraft, focusing on precision, adaptability and digital integration.
By combining reverse engineering, intelligent process adaptation and variability-aware tooling, the project created an integrated wing box assembly cell that achieves part-to-part assembly accuracy without relying on costly, fixed tooling.
VADIS built upon the latest advances in digital design, metrology and process automation to deliver a demonstrator capable of achieving ultra-high precision (±0.006 mm) while significantly reducing production cost, waste and time.
The project was a part of the Clean Sky 2 Joint Undertaking, a major European research initiative supporting sustainable aviation innovation.
Aircraft manufacturers face increasing pressure to reduce cost and improve production flexibility while meeting strict quality and tolerance standards. Traditional wing assembly techniques depend on fixed tooling and manual intervention, which make it difficult to adapt to design variations or production rate changes.
VADIS addressed these challenges by introducing deterministic, variability-aware assembly methods that use real-time metrology and adaptive digital twins. These technologies allow manufacturers to dynamically compensate for part deviations, improving overall accuracy and reducing reliance on rigid fixtures.
Through its high-tolerance deterministic assembly philosophy, VADIS directly tackles manufacturing inefficiencies that contribute to parasitic drag, a key factor affecting aircraft fuel burn and emissions.
The project’s objectives were focused on establishing new standards for precision and adaptability in aerospace assembly:
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Develop high-accuracy metrology systems that maintain precision across large working volumes
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Optimise part-to-part wing box assembly processes for improved aerodynamic performance
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Conduct geometrical tolerance analysis and assessment to define feasible tolerance ranges
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Design and validate a self-adaptive assembly fixture for dynamic process control
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Integrate a digital twin of the spar-rib-skin assembly for real-time data feedback and process adaptation
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Achieve ±0.006 mm precision in reverse engineering and validation tests
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Demonstrate adaptive process capability through physical test cell assembly at Omnifactory
These developments culminated in a fully functional integrated wing box assembly cell, representing a major leap forward for aerospace manufacturing.
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The University of Nottingham, working alongside Electroimpact and Leonardo, developed and tested key components of the VADIS concept within the Omnifactory facility.
The project’s demonstrator successfully combined advanced metrology, predictive simulation and intelligent control systems to achieve part-to-part assembly without the need for dedicated tooling.
Key results and deliverables include:
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Variability analysis and characterisation of fixture and process tolerances
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Process capability assessment and tolerance range widening for improved design flexibility
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Benchmarking and design of a self-adaptive fixture and integrated metrology system
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Adaptive digital twin capable of real-time model updating and process adjustment
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Demonstration of reverse engineering precision at ±0.006 mm
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Inspection-assisted predictive shimming and fettle for improved surface fit
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Computer-aided tolerance optimisation for assembly sequence planning
By integrating these technologies, the VADIS project demonstrated a new level of digital and physical collaboration between design, manufacturing and inspection processes.
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The VADIS project contributes directly to the Clean Sky 2 Fixed Wing Airframe Integrated Technology Demonstrator (ITD) and supports the wider European effort to reduce the environmental footprint of aviation.
Through precision-driven digital manufacturing, VADIS delivers multiple long-term benefits:
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Reduced tooling costs through reconfigurable and adaptive assembly systems
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Improved aerodynamic efficiency by minimising panel gaps and parasitic drag
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Enhanced manufacturing flexibility allowing faster adaptation to design or rate changes
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Sustainability gains through reduced waste, rework and material use
The outcomes of VADIS also strengthen Europe’s capability to develop highly flexible and accurate manufacturing systems, enabling faster response to market and regulatory demands.
The project’s findings will inform future research in metrology-assisted adaptive assembly, tolerance management, and digital twin integration, contributing to ongoing work at the University of Nottingham’s Institute for Advanced Manufacturing (IfAM).
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Working with the team at the University of Nottingham was critical to our demonstration and validation of novel wingbox assembly processes. Collaborating on this project combined industrial requirements from Leonardo S.p.A., ElectroImpact’s automated tooling and fixturing expertise, and pioneering measurement and optimisation methods from University of Nottingham, to create a bespoke solution that otherwise
would not have been possible.
Gianni Iagulli, Head of Manufacturing,
Research & Development,
Leonardo S.p.A.
