Customer Profile: Manufacturer in the Aerospace & Defense Industry
Application: Precision tube handling and laser cutting
The Challenge
A leading aerospace and defense manufacturer needed a highly customized solution to automate the delivery and laser cutting of sub 1/10th of an inch, 16-foot-long tubing. Their existing manual process was time-consuming, inconsistent, and posed safety and quality risks—particularly when dealing with tight tolerances and delicate materials.
In addition to automating tube delivery and laser cutting, the customer had a critical requirement:
The interior of the small-diameter tube needed to remain dry and as free of any debris or particulates as possible to meet strict aerospace cleanliness standards.
This added a layer of complexity to both the mechanical design and the integration of cutting technology.
Solution
Sure Controls engineered and delivered a fully integrated automation cell designed specifically to meet the customer’s unique requirements—with a focus on both precision and cleanliness.
Key Features:
- Automated Tube Delivery System
The custom cell precisely handles the small tubes, automatically feeding and positioning them with high accuracy. The system was designed to avoid stress or vibration that could compromise alignment or introduce contamination. - Precision Laser Cutting
The laser cutting system was finely tuned to create high-quality cuts without generating internal debris, addressing the customer’s strict cleanliness needs. Exhaust and filtration systems were also integrated to capture particulates at the source. - Customizable HMI
A tailored Human Machine Interface (HMI) allows operators to select recipes, adjust parameters, and monitor the process with ease—reducing operator error and enhancing flexibility. - Vision Guidance System
Integrated camera systems provide alignment verification to ensure precise material positioning and cutting. The system continuously monitors for deviations and ensures consistent results. - Enclosed Safety Cell
The entire solution is housed in a safety-rated enclosure with interlocks, shielding operators from laser exposure and meeting aerospace safety compliance requirements.
Results
Since implementation, the customer has experienced major improvements in performance, safety, and quality:
- Reduced Cycle Time by automating long-format material handling
- Increased Accuracy with guided laser cuts and vision alignment
- Improved Safety through smart guarding
- Large Internal Debris reduction thanks to precise laser tuning capabilities
- Enhanced Flexibility via user-friendly HMI and recipe control
See It in Action
Watch the solution deliver a 16-foot tube and execute a high-precision, debris-free laser cut—all under smart automation and safety controls.
