High-precision robotics gains ground in aero-structure manufacturing
Composite aero-structures, typically based on carbon fibre epoxy resins, are vital for reducing weight, increasing strength, and improving fuel efficiency in modern aerospace. Their use in fuselages, wings, and stabilisers delivers a longer service life and greater corrosion resistance than conventional metals
The production and machining of these components requires extremely tight tolerances. Despite standard industrial robots providing flexibility, they lack the rigidity and precision to meet such demanding requirements. Ideko, a technology centre with experience in developing advanced manufacturing solutions, has overcome these limitations by bringing the performance of industrial robots closer to that of precision machine tools.
At the upcoming edition of the International Machine Tool Biennial (BIEMH), the centre will present the results of the work carried out in an intelligent robotic cell integrating drilling, deburring and inspection operations on a composite aero-structure representative of an aircraft wing.
The demonstrator will underline the technologies, methodologies, and tools developed by the centre for manufacturing these components, reducing robot positioning errors during machining tasks.
Combining advanced capabilities
When designing and developing these high-precision robotic cells, Ideko combines several advanced technological capabilities,
In the design and development of these high-precision robotic cells, IDEKO combines several advanced technological capabilities, positioning itself as a leading player in applied R&D&I for the aerospace industry.
The centre’s expertise in photogrammetric measurement technologies has led to the development of an innovative computer vision system that continuously tracks the robot's end effector across large working volumes and corrects its position in real time. The solution integrates predictive models, optimises meteorological performance, and enables automatic camera repositioning based on the machining trajectory.
Ideko has also enabled the robot to perform automatic component referencing, generate and adapt movements to real parts once clamped in fixtures, and automatically adjust machining operations to the measured geometry. These advances reduce the need for manual adjustments and enhance process repeatability.
Ideko has integrated technologies to achieve more efficient, intelligent, safe, and sustainable machining. These solutions work to prevent common defects in composite materials, such as delamination. Additionally, the centre has developed and validated systems to contain and extract the toxic dust generated during machining operations.
The incorporation of advanced sensing technologies enables the identification of potential issues, such as vibrations, in real time, facilitating timely intervention in the process. These digitalisation and advanced analytics capabilities enhance surface quality, extend tool life, and improve workplace safety.
To address the structural limitations of commercial robots, the centre has developed expertise in defining and validating robotic cell architecture. This know-how is complemented by strong capabilities in the conceptual design and commissioning of advanced fixtures for clamping and referencing large components, tailored to composite aero-structures.
In this work, Ideko considers critical aspects such as robot and machining head accessibility to all functional areas of the component; control of deformations caused by gravity and the clamping system; compatibility with automatic referencing and digitalisation systems; and positioning repeatability in machining operations.
This portfolio of technologies, aimed at optimising industrial robotics performance in aerospace production, will be showcased on Ideko’s stand in Hall 1 at the Bilbao Exhibition Centre (BEC) from March 2 to 6, 2026.
