Rapid on-demand re-engineering of certified aircraft interior parts

Replacement interior parts are essential to aircraft operations, and there is a need for rapid re-engineering of replacements without access to original part data and with only remote access to the part. This is compounded by the considerable complexity and constraints from aviation certification, to present a unique and unresolved challenge. This paper presents a methodology for Rapid On-demand re-engineering, certification, and manufacturing of Aircraft Interior Replacement parts (RO-AIR). The methodology integrates Industry 4.0 technologies, including additive manufacture and model-based engineering. Detailed development, critical relationships and decision-making is then presented for three key aspects: remote geometry measurement or “capture”; certification; and operations. Two case studies from real aircraft parts are used as demonstration, and it was found that RO-AIR outperformed traditional manufacturing methods by reducing lead time up to approximately 60% and 77% for the simple and complex parts considered. The outcomes of this work have broad applications for aircraft maintenance and spare parts manufacturing, which may also extend to primary and secondary aircraft parts.