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Following GKN Aerospace’s recent announcement that it has extended its design capability with Vistagy’s SyncroFIT application, Simon Lott looks at how the software will help the tier one manufacturer make substantial savings throughout the design evolution process.


Boeing 767 blended winglet: On the assembly line at GKN Aerospace THE HOLISTIC


developer’s FiberSIM product over the last eight years to aid in the design of composite aerostructures, including Boeing 767 winglets, the addition of SyncroFIT now allows the manufacturer to cut down on repetitive assembly design tasks and reduce errors that could lead to costly redesign work. As part of Vistagy’s Aerosuite design and manufacturing solution, SyncroFIT has been developed to work in conjunction with 3D CAD systems to efficiently manage the complexities of airframe interfaces with a particular emphasis on fastened structures. The first major GKN project to take advantage of SyncroFIT will be the design optimisation of Bombardier CSeries winglets, a project potentially worth over US$100 million between now


W


hile GKN has been a long time customer of Vistagy, having used the US software


APPROACH


and 2025 and which is currently in the design definition phase. FiberSIM enables designers to


develop composite parts while taking into consideration key data, such as thickness requirements, stacking sequences, and structural interface requirements. With tight links between FiberSIM and FEA programs, composite parts can be optimised to achieve the required stiffness at the lowest possible weight. Just as FiberSIM is a dedicated solution for managing composite part design, SyncroFIT similarly addresses challenges at the aerostructure assembly level. By managing the joints and the massive quantity of fasteners within the assembly, SyncroFIT enables designers to automate tedious design tasks and react quickly to the inevitable changes that occur during airframe development processes.


Excluding the immeasurable saving on


redesign work caused by errors, Vistagy quotes a typical time and cost saving of 45% related to assembly design through the removal of repetitive tasks, such as referencing and updating external information and adapting to changes. Just as important for GKN however is the additional freedom it allows for rapidly updating the assembly definition and fastener bill of materials when changes to the composite structure occur. For example, one of the bigger headaches in composite assemblies is locating and sizing fasteners, with designers traditionally having to position these conservatively, such as well away from ply drop regions, adding weight and cost to a structure that is regarded as one of the most weight critical on the aircraft. However, with the greater visibility of the overall product allowed by SyncroFIT, engineers can optimise


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