Breaking the Mold: Solideon's Aperture System Sets New Standards in Aerospace Manufacturing

Manufacturing is a critical component of the aerospace industry. From design to machining, assembling, and testing, the process can be time-consuming and costly, so attention to detail and minimizing error are of the utmost importance. However, traditional manufacturing processes are filled with inefficiencies. As technology evolves, so does the need for better, more efficient processes. 

Traditional aerospace manufacturing is segmented, with components usually produced separately and integrated later on at a separate facility. This presents a problem, as any changes to one component will require re-evaluation and adjustments across other stages, causing delays and increased costs. The process to deploy a prototype of a new system in aerospace in defense now takes upwards of 10 years and hundreds of millions of dollars. 

“Traditionally, manufacturing, even 3D printing, is segmented. For example, in building the body of an aircraft, you might be able to 3D print it, but you still have to integrate things like electronics, flight control systems, avionics, etc. People are focused on printing components, which are then taken to somebody else to integrate. Or maybe they integrate it themselves, but the manufacturing technology doesn't talk to itself,” says the CEO of Solideon, Oluseun Taiwo.

Other limitations of traditional manufacturing include high costs due to manual labor that can also result in human error, a lack of flexibility when adapting to changes, and inconsistency in quality. An aging workforce combined with societal trends will make it rare to have an adequate manufacturing labor force in the coming decades. To address these inefficiencies, Solideon is harnessing the power of additive manufacturing to produce parts faster with reduced components, minimized waste, and free from the limitations of conventional tooling. With its state-of-the-art collaborative robotic additive manufacturing system, Aperture, Solideon is addressing the shortcomings of traditional methods.

Aperture combines 3D printing, CNC machining, inspection, and assembly into one cohesive end-to-end platform, eliminating the need for separate stages where information can be lost or miscommunicated. It also allows for real-time updates and adjustments and minimizes delays and machine downtime, improving overall efficiency.

“We have a multi-robotic system in Aperture to combine as many manufacturing processes as possible post-3D printing into our cell. The moment you change one thing, you instantly can change everything about it without having to go through weeks or months of understanding that change in relation to it,” states Taiwo.

All data generated during the manufacturing process is stored in a cloud-based system. Due to its all-in-one nature, Aperture documents every step of the manufacturing process, ensuring that critical information is captured accurately so Aperture can autonomously iterate and improve the manufacturing process in real-time. Taiwo explains, “Instead of just printing a part, we go after an entire product. The interesting thing is that those learnings stay internally within the company, and we can make even better products over time because all that data now lives in a living, breathing space that gets updated over time as we work with more customers.”

As Aperture prints and assembles, it also builds a digital twin to create virtual replicas of physical components and systems. This allows for real-time feedback and helps identify potential issues so that necessary adjustments can be made in advance. The digital twin continuously monitors the condition and performance of manufacturing equipment, predicting maintenance needs before they result in downtime. 

The name Aperture refers to the adjustable opening in a camera lens that allows light to enter and create an image. In this context, Aperture symbolizes a focused approach to manufacturing in space, utilizing multiple synchronized robots that work together and resemble the mechanical movement of a camera's aperture.

“We named it Aperture because it's a snapshot of humanity's future. When you look at it, it's multiple robots that sit in a ring around each other to be able to build one thing. So if you look from the top view, there are so many robots working together collaboratively, it almost looks like the aperture of a camera,” says Taiwo. 

In capturing a snapshot of humanity on Earth, Aperture paves the way for Solideon to reach its ultimate goal of being the first company to manufacture entire products in space, for space. The ultimate vision is for these manufacturing technologies to create a self-sustaining presence for humanity in space, making it possible to build and maintain necessary infrastructure directly in orbit. 

By first developing and perfecting these technologies on Earth, Solideon is laying the groundwork for a future where manufacturing in space is not only possible but essential for space exploration and habitation. To learn more, visit solideon.com.