British defence manufacturer BAE is set to adopt smart manufacturing for the next generation fighter it is developing for the UK, Italy and Sweden. BAE plans to make 30 percent of the Tempest 5th Generation fighter using 3D printing, and 50 percent will be assembled by robots. The company has told its suppliers to prepare for big changes in the way they develop and make advanced aircraft components.

BAE is leading a consortium, Team Tempest, that includes British aero engine manufacturer Rolls Royce, Italian aviation manufacturer Leonardo S.p.A., and European missile maker MBDA, to manufacture a 5th generation fighter. Saab, which manufactures the Gripen 4th generation fighter, is working with BAE on the Tempest, but is not a member of the consortium. The Italian and Swedish Governments have joined the British in establishing requirements and supporting development of the new fighter.

BAE is building a new “intelligent and smart” factory to increase productivity and “revolutionise” combat aircraft production in the UK.

The new factory will incorporate Industry 4.0 digital technologies and advanced manufacturing strategies.

The new facility at BAE Systems’ site in Warton, Lancashire, is the result of a multi-million pound investment and collaboration with more than 40 blue chip and SME companies along with academic institutions. The new factory is a digitally connected, intelligent factory specifically designed for future military aircraft production.

The factory aims to bring together advanced manufacturing technologies to transform engineering processes. Automated robots, virtual and augmented reality will increase speed, precision and efficiencies, as well as reduce the costs associated with the manufacture of complex military aircraft structures.

The new factory at Warton will pioneer new approaches to how humans and machines can operate together. According to BAE, cobotic and flexible robotic technologies remove the need for heavy, fixed, long-lead tooling and can quickly switch from the manufacture of one item or platform to another.

Intelligent machines and off-the-shelf robotic technology from the automotive industry have been modified to operate at the precise tolerances required for military aircraft, which are less than a third the width of a human hair on some BAE programmes.

The new factory aims to deliver the new fighter more cost-effectively and in half the time of previous programmes.

“We’ve collaborated with the best of UK industry and academia to develop a cutting-edge facility that combines current and emerging technologies, ensuring the UK remains at the forefront of combat air technology development,” said Dave Holmes, Manufacturing Director for BAE Systems Air. “Driving our manufacturing capabilities forward as we prepare for the fourth Industrial Revolution, will sustain and develop critical skillsets and ensure we can continue to deliver military capability to address future threats, whilst improving productivity and delivering value for money for our customers.