Case studies

Additive Layer Manufacturing Facility

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Our client are one of the world’s largest, independent, first tier suppliers to the global aviation industry. Drawing upon over 100 years of aerospace experience, considerable knowledge and superior manufacturing technologies, our client supplies high-value, integrated assemblies in both metallic and composite materials.

21

degrees (+/-1) control

<40%

BMS

system

Client's Requirement

Our client required the construction of a controlled environment, advanced manufacturing area for their additive layer manufacturing (ALM) solutions. ALM is a process where components are created layer by layer, enabling complex structures to be produced directly from 3D CAD models; a game-changing development for the aerospace manufacturing industry.

Our Solution

Bouygues Energies & Services were appointed as the turnkey design & build partner for this project. Through a collaborative approach to the design, we delivered a ‘box within a box’ construction solution, using composite walls and ceilings. This met the client's requirement of an area built within the existing building, which would still remain independent from the building’s structure. All floors were levelled and finished to the standard of new areas, ensuring succinct amalgamation of the old areas with the new.

Our in-house design teams designed a full HVAC system to control humidity and temperature within the manufacturing area, managed by a networked BMS system. The design solution incorporated provision of close control temperature and humidity within the 21 degrees (+/- 2) and <40% RH.

Working within the live operational site, our team installed lighting levels, gases and compressed air in order to meet specific client equipment requirements. We tested and commissioned the facility before handover to ensure that high standards had been maintained throughout the project for prime client usability.

Client Benefits

A single point of accountability
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, and commissioning to offer seamless engineering solutions to the challenges facing our client.

Cutting edge facility
The ALM process is the next step in efficient aircraft manufacture and the completion of this facility provides our client with the correct environment to utilise ALM, manufacturing ‘first of their kind’, additive layer aircraft components.

Innovative manufacturing capabilities
ALM capability will mean that lead times will be reduced, manufacturing will be more efficient and more innovative products can be created, improving prospects for both our client and theirs.

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