Wedoany.com Report-Nov. 17, At Airbus headquarters in Toulouse, France, and in the presence of King Willem-Alexander and Queen Máxima of the Netherlands, Airbus Helicopters signed a letter of intent (LOI) to adopt digital automation technologies from Airborne, based in The Hague, Netherlands, for its Le Bourget factory. The initiative aims to optimize manufacturing efficiency and output for composite rotor hubs and helicopter blades using Airborne’s software and automation systems, specifically Automated Ply Placement (APP) and Kit by Light (KBL).

The project focuses on integrating new automation and software solutions to enhance productivity and efficiency. Airbus’ Le Bourget facility produces all composite helicopter blades and hub structures for both military and civil models. Marcus Kremers, CTO of Airborne, said: “It's a high-mix production environment, ramping up to meet increasing demand, and Airborne’s industrialization technologies are an excellent fit.”

The APP system, already used by Airbus Commercial for the A350 program, automates the layup process from cutter to laminate. It can handle both prepreg and dry fiber materials, both of which are used at Le Bourget. For this project, new functionalities will be introduced to manage part size, layup, and quality inspection, further improving operational performance.

KBL, which is in use at Airbus Helicopters’ Donauwörth plant in Germany, supports operators in the cutting room by accelerating the kitting process through software guidance. Plans are in place to implement KBL at Le Bourget to reduce material waste, increase output, and streamline production workflows.

The adoption of Airborne’s technologies at Le Bourget is expected to enhance manufacturing efficiency in a high-mix production environment while supporting Airbus Helicopters’ growth to meet rising demand for rotorcraft components. By combining automated layup and optimized kitting solutions, Airbus aims to improve both quality and productivity across its helicopter manufacturing operations.

This collaboration highlights Airbus Helicopters’ commitment to leveraging advanced digital automation to strengthen production capabilities, reduce waste, and improve operational efficiency in key facilities. The integration of APP and KBL reflects best practices developed at Airbus Commercial and other Airbus Helicopters sites, tailored to the specific requirements of composite rotor hub and blade manufacturing.

Overall, the project represents a step forward in industrial automation, combining advanced software, robotic processes, and operator support tools to achieve higher throughput and improved material utilization while maintaining strict quality standards for both civil and military helicopter programs.