Lancashire aircraft makers are shaping the future thanks to technology

Engineers in Lancashire are testing models of the next generation of combat aircraft which could be built in the UK.
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And the team based mainly at Warton, but also at Samlesbury and Brough in Humberside, are making heavy use of digital technologies to streamline the process of designing the new aircraft which could be in service by 2035.

Using the latest digital twin technologies, shapes for the aircraft were designed virtually and tested by high-performance computers able to calculate the aerodynamic performance of different aircraft features and test pilots taking Tempest to the skies from a ground based simulator.

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Then scale models were 3D printed and put through their paces at BAE Systems’ wind tunnel facilities at Warton, to physically test the aerodynamic properties of the design under harsh wind speeds of more than twice the speed of sound.

A 3D printed model of the Tempest being tested in a wind tunnel at WartonA 3D printed model of the Tempest being tested in a wind tunnel at Warton
A 3D printed model of the Tempest being tested in a wind tunnel at Warton

The wind tunnels at Warton can consume 15 tons of air in 20 seconds when running at full power. They can run at subsonic, transonic and supersonic speeds, and have played a crucial role in the development of BAE Systems’ most successful military aircraft programmes in the past.

Paul Wilde, Head of Airframe Technologies, Tempest said: “The digital twin concept we have developed will be used to design, test and support every single system and structure for Tempest.

"By taking an entirely digital approach to the challenge the UK Government has set us, we’re transforming the way we work and adding incredible value to the programme.

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"We can achieve what traditionally would have taken a number of months in a number of days. As a result, we’re working faster for the future and we’re using the virtual environment to create endless opportunities for our engineers to experiment without boundaries, and with open minds – key to the future innovation of the programme.”

BAE Systems is working closely with Rolls Royce, Leonardo and MBDA as part of Team Tempest to explore more than sixty technology areas in total, experimenting with different ideas ranging from the physical shape of an aircraft to the sophisticated sensors that will become the brains of a future system.

The digital approach has also been adopted in the development of a first of its kind Factory of the Future at Warton in Lancashire which BAE Systems is currently using to demonstrate how the future fighter aircraft could be built.

Data from intelligent robots, supply chain databases and machines is digitally threaded together to deliver increased efficiency and accuracy in the manufacturing process.

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Michael Christie, Director, Future Combat Air Systems, BAE Systems said: “Designing an aircraft has traditionally been an opportunity which comes up once in someone’s career which causes real challenges of transferring skills and knowledge.

"The technologies now available to us mean that we can reduce the design cycle which in itself is good for the affordability of a programme but we can also perform more cycles very quickly until we get it right.

BAE Systems are using data from the trials, combined with research across the programme and together with its Team Tempest partners to contribute towards the development of an Outline Business Case to be considered by the UK Government, which is scheduled to be the next major decision point on commencing the next phase of a Combat Air Acquisition Programme for the UK.