With our many years of experience in working on modern sailplanes combined with our ability to machine parts on our CNC routers we were asked to create a full size models for the A400M engine nacelle by GKN Aerospace Test Facilities.
Using CATIA model data and importing it into our CAM software we were able to cut accurate skin profile in block foam before skinning with a mixture of glass and carbon fibre fabrics.
By combining the accuracy of CNC machining with traditional hand skill the model was brought to life. All aspects of the work were completed within our own workshops allowing us to control the overall design and construction methods. The final model had an overall length of 3.5 mtrs and a width of 1.25 mtrs. When checked for accuracy using CMM methods it was confirmed to be within 0.5% of drawing.
The project took us just over 4 months to complete from initial receipt of CAD models to delivering it to the customer.
This high profile project for a major Aerospace customer demonstrated Severn Valley Sailplanes ability to carry out large scale projects within budget and a tight time frame.