Zünd and Loop Technology partner to advance composite aerostructure manufacturing

Zünd is renowned for its precision cutting systems, known for speed and adaptability across industries. This makes them a perfect partner for Loop Technology, which excels in developing automation systems that enhance efficiency and accuracy. Zünd CEO Oliver Zünd said, "Collaborating with Loop Technology is a natural progression for us. Our cutting systems push the limits of precision, and integrating with Loop Technology’s FibreLINE system will drive advancements in composite manufacturing that benefit the aerospace sector."

The integration of Zünd’s biggest cutter ever with Loop Technology’s FibreLINE system marks a transformative step forward in composite aerostructure production. FibreLINE is an end-to-end automated preforming system that revolutionizes the manufacture of composite structures. This collaboration combines Zünd’s custom-engineered, largest-ever Q-Line cutter, designed to work seamlessly with the world’s largest industrial robots, to deliver unmatched cutting capabilities, speed, and accuracy. This modular adaptation of the Q-Line cutter with Loop Technology’s FibreLINE system offers a future-proof, scalable solution that perfectly meets the increasing demands of the aerospace sector. The proven reliability and longevity of Zünd equipment are key reasons for this partnership. Alun Reece, Owner and Managing Director at Loop Technology, described the partnership as revolutionary for the industry: "This tailored solution is designed to deliver faster cutting speeds whilst significantly reducing the potential for stray fibers, which is a common challenge in composite manufacturing. The result is higher accuracy in ply cutting and more precise preforms, which are critical for the integrity and performance of aerostructures."

A recent article from Farnborough 2024 highlighted Boeing's forecast for nearly 44,000 new airplanes through to 2043, driven by air travel surpassing pre-pandemic levels. Pairing Loop Technology’s FibreLINE automation with Zünd digital cutters provides faster cutting, reduced stray fibers, higher ply accuracy, and more precise preforms. This will help meet the significant growing demand for lighter commercial aircraft and supports the aviation industry’s goal of reaching net zero emissions.

Zund UK worked closely with Loop Technology to develop a modular solution derived from the Q-Line, adaptable to customer needs and incorporating cutting-edge technology for aerospace manufacturing. Loop Technology's FibreLINE system is set to be installed at the University of Sheffield’s Advanced Manufacturing Research Centre. This cutting-edge, high-rate preform manufacturing system is designed to pick and form composite sheets (plies) into intricate 3D double-curvature profiles. It then precisely places them onto a tool, inspects, and heat-stakes the components, preparing them for the next stage of production. Targeting high precision and deposition rates in excess of 200Kg/hr the process presents opportunities for smaller factory footprints and significant downstream assembly benefits in high rate applications.

As aerospace manufacturers increasingly turn to composites for their unparalleled strength-to-weight ratio, the demand for advanced and efficient manufacturing solutions continues to grow. The collaboration between Zünd and Loop Technology is integrated with research and development programs involving major OEMs and other suppliers to combine digital cutting technology with automation. This collaboration aims to boost productivity and tackle industry challenges head-on, delivering solutions that are faster, more accurate, and contribute to the overall sustainability of the aerospace sector. Nicki Kay, Managing Director at Zund UK said: “At Zünd, we are committed to pushing the boundaries of what’s possible in manufacturing. This partnership is just the beginning. We are excited to explore new possibilities and continue to innovate in ways that will benefit not only the aerospace industry but all sectors that rely on advanced composite materials”.