SciTransfer
UPBEAT · Project

Reducing Aviation Part Costs and Weight through AI-Driven Manufacturing Certainty

transportTestedTRL 4

Imagine building a plane part where you can predict exactly where a tiny flaw might appear before you even make it. Instead of over-engineering parts to be heavy just to be safe, this tech uses smart math and sensors to prove a part is strong enough. It's like having a high-tech X-ray and a crystal ball combined for aircraft engine components.

By the numbers
20-40%
weight reduction
50-70%
fewer defects
30-40%
reduced qualification time
25-35%
reduced qualification costs
30-50%
lower manufacturing costs
20-30%
lower manufacturing time
The business problem

What needed solving

Aviation manufacturers rely on oversized safety margins because they cannot accurately predict material randomness. This leads to heavier parts, slower certification, and higher production costs.

The solution

What was built

A hybrid metal-composite Outlet Guide Vane (OGV) demonstrator and a set of uncertainty quantification (UQ) tools integrating machine learning and in-situ monitoring.

Audience

Who needs this

Aerospace engine OEMsAdditive manufacturing service providersComposite materials engineersAviation safety certification agencies
Business applications

Who can put this to work

Aerospace Manufacturing
enterprise
Target: Jet engine component manufacturer

If you are a manufacturer dealing with high scrap rates in engine parts — this project developed uncertainty quantification tools that can lead to 50-70% fewer defects and lower manufacturing costs by 30-50%.

Aviation Certification
enterprise
Target: Aircraft certification body or OEM

If you are an OEM dealing with slow and expensive part qualification — this project developed virtual certification methods that reduce qualification time by 30-40% and costs by 25-35%.

Advanced Materials
SME
Target: Composite and 3D printing specialist

If you are a materials supplier dealing with the difficulty of joining metal and carbon fiber — this project developed a hybrid interface for Outlet Guide Vanes that can reduce part weight by 20-40%.

Frequently asked

Quick answers

How does this reduce manufacturing costs?

By implementing in-line quality assurance and advanced predictive capabilities, the project aims to lower manufacturing costs by 30-50%.

Is this technology ready for industrial scale?

The project is currently demonstrating these technologies using a specific aviation use case, the Outlet Guide Vane (OGV), to prove scalability in engine aerostructures.

What is the IP or licensing status?

Based on available project data, specific licensing terms are not listed, but the project involves a consortium of 6 partners including 3 industrial entities.

How does it affect the certification timeline?

The use of Virtual Certification and uncertainty quantification is expected to reduce qualification time by 30-40%.

Can this be integrated into existing production lines?

Yes, the project specifically focuses on in-line quality assurance support to reduce manufacturing time by 20-30%.

Consortium

Who built it

The consortium is highly balanced for commercialization, featuring a 50% industry ratio with 3 industrial partners and 3 research organizations. The presence of 2 SMEs suggests a focus on agile implementation and specialized technology transfer, while the coordination by SINTEF AS provides a strong research-to-industry bridge across Norway, France, and Sweden.

How to reach the team

Contact SINTEF AS regarding the UPBEAT project outcomes

Next steps

Talk to the team behind this work.

Contact us to connect with the UPBEAT consortium for licensing these UQ tools.

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