Modular Aircraft Tooling Interface for Efficient Manufacturing

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Solution Overview

Problem

Existing aircraft manufacturing methods lack efficiency and flexibility in producing modular aircraft designs, particularly for blended wing body (BWB) aircraft, which require unique interior designs and efficient high-lift wings.

Innovation Solution

A system and method utilizing common and modular tooling components, along with a tooling interface, to manufacture fuselage and collar components of modular aircraft, enabling the integration of common and modular components across various aircraft configurations, including BWB designs, using techniques such as injection molding, die casting, carbon fiber layup, and additive manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional aircraft manufacturing methods are used, then structural integrity can be maintained, but manufacturing efficiency and flexibility are reduced

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidtooling system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The tooling system is divided into common tooling components ( reusable for multiple aircraft) and modular tooling components (configurable for specific configurations). This segmentation allows efficient manufacturing across different aircraft types while maintaining structural integrity through standardized interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The common tooling components are designed to be universal and reusable across multiple aircraft configurations. The tooling interface component enables these common components to work with different modular components, providing multi-functionality and reducing overall tooling complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If modular tooling components are used for each aircraft configuration, then manufacturing flexibility is improved, but tooling system complexity increases

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidtooling system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The tooling system is segmented into common reusable components and modular configuration-specific components. This allows flexibility for different aircraft configurations while managing complexity through standardization of the common portions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tooling interface component serves as an intermediary that connects common tooling components with modular tooling components. This mediator enables flexibility across configurations while simplifying the overall system by providing standardized connection points.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If custom tooling is manufactured for each aircraft type, then manufacturing precision can be maintained, but production time increases

Engineering Contradiction:

Improvecomponent manufacturing precisionVSAvoidtooling setup time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Common tooling components are pre-manufactured and standardized in advance. This preliminary action ensures manufacturing precision is maintained while reducing setup time for different aircraft configurations, as the common tooling is already prepared and can be quickly paired with modular components.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If traditional manufacturing methods are used, then structural integrity is maintained, but cost-effectiveness decreases

Engineering Contradiction:

Improvecost-effectivenessVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The tooling system is segmented into common and modular components, allowing cost-effective manufacturing through reuse of common tooling while maintaining structural integrity through precise modular components for each aircraft configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tooling system allows parameter changes between different aircraft configurations by swapping modular components while keeping common tooling parameters standardized. This enables cost-effective production across variants while maintaining the reliability needed for structural integrity.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250205935A1Systems and methods for manufacture of a modular aircraft

Publication Date: 2025.06.26 JETZERO INC

AI summary

A system for manufacturing modular aircraft includes at least a common tooling component, wherein the at least a common tooling component is configured to manufacture at least a flight component. The system includes at least a modular tooling component, wherein the at least modular tooling component wherein the at least a modular tooling component is configured to manufacture at least a fuselage component and a collar component. The system includes at least a tooling interface component, wherein the at least a tooling interface component is configured to mechanically connect the at least a common tooling component at a first end to the at least a modular tooling component at a second end.