CASE STUDIES
WINGLIFT
ELCAT | FLEXCELLE | MADE SMARTER | ELASTIC | ASTRAL | AUTORAMP | SMARTER | CASE STUDIES
WING LEAN INNOVATIVE FUTURE TECHNOLOGY
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The WingLIFT project developed and demonstrated advanced robotic guidance systems and smart digital integration technologies for composite wing assembly, supporting the next generation of high-performance, cost-effective aircraft.
Running from July 2017 to March 2021, WingLIFT aimed to help the aerospace sector meet rising global air travel demand while reducing production costs, improving efficiency and maintaining precision.
The project directly contributed to Airbus’s Wing of Tomorrow programme, advancing digital manufacturing and automation technologies to support the industrialisation of lightweight composite wing structures.
The aerospace industry is under continuous pressure to deliver aircraft that are lighter, more fuel-efficient and environmentally sustainable, while maintaining uncompromising standards of precision and quality.
Traditional wing assembly processes rely on extensive manual intervention and static tooling, which increase production time, cost and risk. To meet future manufacturing demands, aircraft manufacturers must adopt digital, data-driven assembly systems capable of delivering sub-millimetre accuracy at industrial scale.
WingLIFT addressed these challenges by developing intelligent robotic control systems and integrated data architectures that enhance accuracy, repeatability and adaptability in composite wing assembly.
The project’s primary objective was to create a foundation for smart, connected aerospace manufacturing through robotics, digital monitoring and open data frameworks.
Key aims included:
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Developing advanced robotic guidance systems for positioning and inspection of large composite components and assemblies
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Creating and demonstrating an open, standards-compliant smart assembly cell architecture
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Implementing and validating intelligent robotic systems capable of positional accuracy better than 0.1 mm
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Integrating real-time data feedback loops for process monitoring, geometric deviation awareness and quality assurance
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Evaluating technologies within industrial demonstrator environments to ensure readiness for adoption
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The WingLIFT project delivered two major technical innovations:
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Advanced robotic guidance systems
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Developed high-precision control algorithms for robotic positioning and automated inspection of large wing components.
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Demonstrated sub-0.1 mm accuracy in positioning tasks.
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Enhanced repeatability and reduced dependency on manual alignment.
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Smart data middleware for digital manufacturing
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Created an open, extensible architecture to connect robotic systems, sensors and metrology tools in a unified assembly cell.
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Enabled intelligent communication between hardware, control systems and analytics tools for real-time decision support.
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Additional research outputs included:
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Comprehensive requirements and baseline studies for composite wing assembly
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Solutions for intelligent metrology and smart integrated assembly cells
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A fully operational technology demonstrator, validated within a live industrial environment
The project built upon earlier work from the Evolvable Assembly Systems programme, extending its digital integration principles to full-scale aircraft manufacturing applications.
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WingLIFT has made a lasting contribution to the UK’s aerospace capability by reducing industrialisation risk for next-generation aircraft, particularly within Airbus’s A320 and A350 programmes.
The technologies developed through WingLIFT have demonstrated how automation and digital integration can dramatically improve both accuracy and efficiency in wing assembly, setting new benchmarks for precision manufacturing.
The project’s impact includes:
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Improved manufacturing precision through advanced robotic guidance
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Reduced development and production costs for composite wing structures
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Faster process validation using integrated data feedback and quality monitoring
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Enhanced competitiveness for industrial partners through adoption of smart manufacturing practices
By combining robotics, metrology and intelligent control, WingLIFT has strengthened the foundation for future digital and autonomous aerospace manufacturing.
All project partners, including Airbus, Spirit AeroSystems and Luebbering, benefited from new technology capabilities, improved efficiency and increased competitiveness in global aerospace markets.
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