Thinking Beyond the Tool

Solving a Complex Aerospace Challenge

Choosing the right installation tool is one thing. Knowing it will work inside a confined aircraft structure before production begins is another.

That was the challenge presented to Alan Burton, Aerospace Account Manager at AIR TOOL SERVICES, when a leading aircraft manufacturer needed to install specialist aerospace fasteners inside a restricted access area of a partially assembled fuselage.

Alan identified a Howmet CT Series installation tool as the right choice for the application. Before making his recommendation, however, he wanted to be certain the tool could be manoeuvred and operated within the limited space available.

Rather than relying solely on technical drawings, Alan worked with Howmet, who supplied detailed CAD models before approaching the University of Lancashire’s Research Knowledge Exchange Service to explore producing full-size 3D printed replicas.

The completed 3D printed models used to validate the tooling application.

Working Together to Solve Engineering Challenges

Air Tool Services has a longstanding relationship with the University of Lancashire, with our directors serving on the University’s Engineering Advisory Panel. This collaboration brought together specialist aerospace tooling expertise and the University’s additive manufacturing capabilities to solve a genuine engineering challenge.

It’s a great example of the approach we take every day. We don’t simply supply tools; we work alongside our customers to understand each application, anticipate potential challenges and develop practical engineering solutions before they become production problems.

Reflecting on the project, Alan said:
“It’s easy to recommend a tool from a drawing. The challenge is making sure it works in the real application. Using a 3D printed model gave everyone confidence before the production tool was ordered.”

From Validation to Real-World Application

With the tooling concept now validated through the 3D printed models, the next stage of the project will see Alan Burton attend the customer’s site to support the installation process and verify the solution in the live production environment.

This next phase will provide the opportunity to test the tooling in a live production environment, demonstrating how the early validation work translates into a successful installation.

The final outcome will not only confirm the suitability of the selected tooling but also provide a clear example of how early collaboration and practical engineering validation can prevent issues before they arise in production.