Advanced Aerospace Manufacturing

Scobee maintains a leading research program focused on advancing metal additive manufacturing technologies for aerospace applications, addressing the challenges of producing flight-worthy components through layer-by-layer fabrication. This specialty encompasses the development of process parameters for high-performance alloys including titanium aluminides, nickel-based superalloys, and aluminum-lithium alloys, optimizing laser power, scan strategies, and thermal management to achieve dense, defect-free microstructures. Researchers at Scobee are investigating multi-material additive manufacturing approaches that enable functionally graded components with varying properties across the part geometry. The work includes developing post-processing protocols including hot isostatic pressing, heat treatment, and surface finishing to achieve aerospace-grade material properties. The facility's research addresses the critical challenge of process qualification and certification, developing methodologies for ensuring that additive manufacturing processes consistently produce components meeting stringent aerospace standards.

The facility operates a comprehensive research program in digital manufacturing technologies that create virtual representations of physical manufacturing systems to enable prediction, optimization, and real-time control. This specialty encompasses the development of digital twin models that simulate manufacturing processes including additive builds, machining operations, and assembly sequences, enabling virtual validation before physical production. Researchers at Scobee are integrating artificial intelligence and machine learning algorithms with manufacturing process data to enable predictive maintenance, quality prediction, and autonomous process adjustment. The work addresses the creation of closed-loop manufacturing environments where sensor data from physical processes feeds back into digital models to continuously refine process understanding and control. The facility investigates the integration of digital thread concepts that maintain data continuity from initial design through manufacturing and into service, enabling comprehensive traceability and lifecycle management of aerospace components.

Scobee maintains extensive capabilities in developing composite manufacturing processes that produce lightweight, high-strength structures essential for modern aerospace applications. This specialty encompasses automated fiber placement and tape laying technologies that precisely orient composite fibers to optimize structural performance, out-of-autoclave curing processes that reduce energy consumption and enable larger structures, and resin infusion techniques for complex geometries. Researchers at Scobee are investigating thermoplastic composite processing that enables welding and reshaping of composite structures, potentially revolutionizing assembly and repair approaches. The work includes developing in-process monitoring systems that track resin flow, fiber placement accuracy, and cure state in real-time, enabling quality assurance during fabrication rather than post-process inspection. The facility's research addresses the integration of multifunctional composites that combine structural load-bearing with thermal management, electrical conductivity, or sensing capabilities.

The facility conducts research in automated assembly systems that enhance precision, consistency, and efficiency in aerospace manufacturing operations. This specialty encompasses the development of robotic work cells for drilling, fastening, sealing, and inspection operations, utilizing collaborative robots that can safely work alongside human technicians. Researchers at Scobee are developing vision-guided robotic systems that can adapt to part variations and tolerances, enabling flexible automation that accommodates low-volume, high-mix production scenarios. The work includes investigating mobile robotic platforms for large structure assembly, where multiple coordinated robots perform operations on aircraft-scale components. The facility addresses the human factors aspects of automation, developing interfaces and workflows that optimize the collaboration between human operators and robotic systems. The research includes developing automated quality verification systems that integrate inspection operations directly into assembly sequences, reducing the need for separate inspection stations.

Scobee maintains an active research program focused on developing advanced inspection technologies that ensure the integrity of aerospace components without compromising their functionality. This specialty encompasses the development of computed tomography systems capable of detecting internal defects in additive manufactured and composite components, phased array ultrasonic testing for complex geometries, and eddy current systems for surface and near-surface defect detection. Researchers at Scobee are integrating artificial intelligence with inspection data to automate defect recognition and classification, reducing reliance on human interpretation and improving consistency. The work includes developing in-situ monitoring systems that track manufacturing process signatures to predict final component quality, enabling proactive process adjustment rather than post-facto rejection. The facility investigates the correlation between manufacturing process parameters and resulting material properties, developing physics-based models that predict component performance based on process data. The research addresses the challenges of inspecting complex geometries and multi-material components, developing hybrid inspection approaches that combine multiple sensing modalities for comprehensive quality assurance.