TPT January 2024

ARTICLE

Schwarze-Robitec GmbH

Case study: the production of highly reliable and precise tubes for aircraft at Tubes and Ducts Moroc Aerospace in Morocco By Schwarze-Robitec GmbH

After all, production of tubes for the aerospace industry requires the utmost precision. There are tight tolerance speci fications to adhere to, and the tubes must be manufactured so that they are completely wrinkle-free in a safe process.

The production of tubes for aircraft is subject to strict requirements, since even the smallest product defects can have fatal consequences. Tubes and Ducts Maroc Aerospace (TDM), a company founded in Morocco, therefore relies on the tube bending machine manufacturer Schwarze-Robitec, whose reliable, robust and precise machines are used to produce tubes of various geometries for aircraft manufacturers. The modern production facility is seen as a showcase project for the country, which is pursuing ambitious goals. TDM was first founded in Morocco in 2018. The company manufactures tubes for the aerospace industry and acts as a Tier 1 supplier for well-known aircraft manufacturers. TDM, which is based at Mohammed V Airport in Casablanca, currently employs 70 people and is a showpiece in the North African country’s strategy to become a major global location for aerospace system and module suppliers in the coming years. To this end, the Moroccan Aerospace Investment Company (MAIC) is investing in businesses like TDM and holds a majority stake. Morocco is aiming to further expand aerospace activities to create local supply chains and make the country a major trading partner. A number of free trade zones have been set up, and the kingdom provides very targeted support for companies in the aviation industry, for example offering financial assistance for employee training and granting other privileges. A competent partner The founders of TDM have more than 60 years of experience in tube manufacturing for the aerospace industry. For the demanding production of tubes for hydraulic lines as well as cooling water, waste water and brake lines in aircraft, they were looking to find a manufacturer of tube bending machines with many years of expertise in the aerospace industry. “We needed a partner who could support us not only with high-quality technology, but also with expert advice,” said Jürgen Viehrig, CEO and co-founder of TDM. “Schwarze Robitec has been active in this field for more than 50 years and knows the special requirements regarding surface finish, wall thickness and ovality down to the last detail.”

Lean manufacturing At TDM’s new production plant, the tubes are first cut to size, then bent and measured. This is followed by the grinding, polishing and joining of tubes with fittings in an orbital welding process. With the aid of a digital X-ray machine, the tubes are inspected, then submitted to a pressure test before they are cleaned and dried. The next stages are then marking, quality assurance, packaging and shipping. For the bending process, the company uses two Aircraft Edition tube bending machines from Schwarze-Robitec: the single-stack CNC 40 E TB and the CNC 40 Rotary with rotating bending head. These bend titanium and stainless steel tubes with diameters ranging from 6.35mm to 31.75mm. “We have the capacity to produce 400,000 tubes a year,” said Mr Viehrig. “Here, we focus not on the production of replacement or special parts, but rather on semi-automated and lean production in large series.” The contracting aircraft manufacturer produces several aircraft in a month, with around 600 different tube systems required for a single aircraft. Each component is a unique piece. To bundle its capacities, TDM manufactures in batches of one to ten, delivers the required quantity and stores the remaining components until the next time the customer requests the parts. For the particularly complex Tubes and Ducts Maroc Aerospace (TDM) manufactures piping for the aerospace industry and acts as a Tier 1 supplier for well-known aircraft manufacturers

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JANUARY 2024