The A380, Leader on Manufacturing technology FARNBOROUGH 20 th /21 st July 2004 Neil HARRIS Presented by

Airbus – A Leader in Manufacturing Techniques 2 AIRBUS CONTINUES TO MAINTAIN ITS LEADERSHIP ON ADVANCED TECHNOLOGIES IN MANUFACTURING Key steps in fabrication High speed cutting Composites Joining technologies Key steps in Assembly Automated Advanced positioning Jig less The A380, Leader on Manufacturing technology

Airbus – A Leader in Manufacturing Techniques 3 Production across the family High cutting volume All metals & composites Sophisticated work piece geometry with thin walls due to lower cutting forces Supported by simplified tooling High performance cutting offers significant cost reduction whilst ensuring minimal waste. A380 – Leader on … HIGH SPEED CUTTING

Airbus – A Leader in Manufacturing Techniques 4 Nearly 20 years experience in primary structures Most advanced tape laying capability and resin transfer moulding (RTM) for integrated parts Ultrasonic scanning systems Elements with high load resistance Airbus sets the standards for efficient manufacturing of high load composite parts. A380 – Leader on … COMPOSITE PRIMARY STRUCTURES

Airbus – A Leader in Manufacturing Techniques 5 Components with carbon fibre resin infusion New components in resin film infusion and advanced layer technology Application to complex curved parts (example pressure bulkhead) Extension of Carbon Fibre Manufacturing technologies to new components reduces aircraft weight. A380 – Leader on … COMPOSITE PRIMARY STRUCTURES Weight savings = less fuel consumption = less emissions

Airbus – A Leader in Manufacturing Techniques 6 Large parts and complex shapes Optimum ply distribution First application on A380 (A380 rear section) Leader in composite applications. Solutions for complex fibre elements A380 – Leader on … COMPOSITE PRIMARY STRUCTURES

Airbus – A Leader in Manufacturing Techniques 7 Fuselage Panels Laser beam welding for integrated panels (lower and side fuselage shells) On-line quality control Elimination of fasteners – reduces weight and reinforces structure A380 – Leader on … LASER BEAM WELDING Welding offers further improvements to the manufacturing of fuselage shells (example weight reduction).

Airbus – A Leader in Manufacturing Techniques 8 New generation of riveting and flexible tooling system drives further cost and cycle time reduction. High performance automated riveting cells for skin panels and “super-shells” Chord dimensions up to 11 m / 35 feet Skin Panel and Shell Riveting Machines A380 – Leader on … AUTOMATED PRODUCTION SYSTEMS

Airbus – A Leader in Manufacturing Techniques 9 Wing Skin Panel Assembly Automation of wing skin assembly in flexible build station Dimensions up to 136 m / 450 feet Automated fastening systems offer additional flexibility and increased output. A380 – Leader on … AUTOMATED PRODUCTION SYSTEMS

Airbus – A Leader in Manufacturing Techniques 10 Avoid requirements for heavy jigs Reduces floor space Improves lead time Laser positioning, best fit methods Advanced positioning optimises work space and improves flexibility across programmes. A380 – Leader on … ADVANCED POSITIONING METHODS

Airbus – A Leader in Manufacturing Techniques 11 Fuselage Assembly Stations Multi-type “jig less” flexible assembly process on aircraft sections Jig less tooling offers a highly flexible concept that can react to changing demands. A380 – Leader on … JIG LESS FLEXIBLE ASSEMBLY

Airbus – A Leader in Manufacturing Techniques 12 Key steps in fabrication High speed cutting Composites Joining technologies Key steps in Assembly Automated Advanced positioning Jig less The A380, Leader on Manufacturing technology Benefits Cost efficient and productive High quality Improved flexibility Environmentally friendly Always “Safety first”

Airbus – A Leader in Manufacturing Techniques 13 AIRBUS S.A.S BLAGNAC CEDEX, FRANCE PRINTED IN FRANCE © AIRBUS S.A.S. 2002, ALL RIGHTS RESERVED AN EADS JOINT COMPANY WITH BAE SYSTEMS