Green manufacturing: the way ahead in aerospace & defence industry
Smart manufacturing in aerospace refers to the integration of advanced technologies, such as 3D printing, digital twins, robotics and automation, and green manufacturing, to optimise production processes, improve efficiency, and enhance product quality.
This manufacturing approach leverages real-time data, predictive analytics, and artificial intelligence and machine learning (AIML) to create intelligent, connected manufacturing systems. Green manufacturing aims to recycle and repurpose materials, especially polymers, to minimise waste and adverse environmental effects. For instance, Global Aerospace (UK) promotes circular economy activities to lower CO2 levels, whereas Plaswire (UK) spearheads recycling procedures that lower carbon emissions. This sustainable method will contribute to the accomplishment of global environmental goals. The production of eco-friendly uniforms, body armour, and other equipment is the main goal of the green defence movement, which is producing biodegradable textiles, recycled polymers, and natural fibres. The use of natural fibres in bulletproof vests instead of Kevlar or other synthetic materials is a fantastic illustration of this breakthrough. According to an Indonesian study conducted in January 2023, natural fibres such as hemp, bamboo, and pineapple leaves are more environmentally friendly and effective in offering dependable ballistic protection. If these natural fiberes are utilised in the production process, manufacturers can significantly lower the weight and price of bulletproof vests without sacrificing stringent safety regulations. Because the industry is so diverse and far-reaching, aerospace companies are pursuing many different strategies for sustainability and eco-consciousness. Some areas being explored include:
Energy consumption: aerospace manufacturers are reducing energy consumption in manufacturing and developing aircraft that consume less fuel or utilise more sustainable energy sources.
Water consumption: many sectors are exploring new manufacturing techniques that consume less fresh water.
Waste reduction: efficient manufacturing practices and strategic buying can result in less waste of materials and unused components. Additionally, aerospace manufacturers are experimenting with both recycled materials and closed-loop recycling systems.
CO2 emissions: many aerospace companies are leveraging the above strategies and others to decrease their carbon footprint or work toward carbon neutrality.
Material selection: many aircraft and component manufacturers are phasing out hazardous materials that may pose a threat to the environment. In the aerospace industry, more than 1,700 materials are subject to regulatory oversight. Initiatives such as the Restriction of Hazardous Substances Directive (RoHS) and the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACh) play a vital role in this shift.
Companies are being pushed to innovate and strive to lower the ecological footprint of military activities, which would specifically target armaments, by environmental regulations and public scrutiny. Fiocchi Munizioni (Italy) has been at the forefront of innovation with its Green Core programme, creating recyclable and biodegradable bullet cores, especially for hunting and precision shooting. By adopting this technology, the US Army at the CAAA is demilitarising obsolete ammunition, including anti-personnel rounds, using robotics. By making munitions recycling safer, quicker, and more ecologically friendly, all these advancements in robotics are revolutionising the defence industry. At the heart of aerospace eco manufacturing lies a quest for materials that balance performance and sustainability. Airbus is exploring bio-sourced resins derived from biological sources such as sugarcane or lignin as alternatives to traditional resins. Another promising avenue is the use of thermoplastic polymers, which offer a weight advantage over carbon composites, are easier to recycle and repurpose, and have less energy-intensive production processes. Alongside material innovations, aerospace manufacturers are harnessing advanced technologies to streamline production and reduce waste. Additive manufacturing, or 3D printing, allows for the creation of complex shapes more efficiently and with reduced material waste.
The implications for the aerospace sector soon are revolutionary. Smart manufacturing is anticipated to improve supply chain transparency by enabling just-in-time production and lowering inventory overheads. Precision manufacturing reduces material waste and energy usage and promotes sustainability. Additionally, the need for human intervention will diminish as autonomous systems develop, enabling quicker manufacturing cycles and fewer mistakes. The aerospace industry's pursuit of eco manufacturing is not without its challenges, particularly in the realm of regulations. The sector faces the daunting task of meeting net zero emissions targets by 2050, which necessitates a comprehensive overhaul of materials and practices. In addition to material innovations and advanced manufacturing technologies, aerospace companies are focusing on optimising energy consumption in their production processes. By adopting energy-efficient machinery and leveraging renewable energy sources, manufacturers can significantly reduce their carbon footprint and operational costs.
Businesses adopting smart manufacturing are well-positioned to take the lead in the cutthroat aerospace industry, offering creative solutions that satisfy the rising demands for sustainability, efficiency, and personalisation. In addition to modernising production, this change paves the way for an industry that is more robust and nimbler.