Precision manufacturing is opening doors in defence sector

By OEM Update Editorial March 30, 2024 12:56 pm

Vineet Seth, MD—South Asia & Middle East, emphasises that Mastercam recognises the burgeoning opportunities within India’s defence and aerospace sectors, driven by government initiatives and increased investments. With precision machining and advanced CAD/CAM capabilities, Mastercam ensures quality, efficiency, and compliance, aligning perfectly with the industries’ evolving needs.

What opportunities does Mastercam see in the defence and aerospace sectors?

The defence and aerospace sectors in India are ripe with opportunities for growth, investment, and innovation. They are driven by government initiatives, increased defence spending, and a focus on self-reliance and modernisation.

First, the Indian government’s initiatives like ‘Make in India’ and ‘Atmanirbhar Bharat’ aim to bolster domestic manufacturing and reduce reliance on imports, which has created a favourable environment for growth in these sectors. Further, India’s defence budget, one of the largest globally and on an upward trajectory, is opening up ample opportunities for companies catering to these sectors.

Recent Foreign Direct Investment (FDI) policies, allowing up to 74 percent FDI in defence manufacturing, are attracting foreign investments and fostering joint ventures and partnerships. These contribute to the modernisation efforts of India’s armed forces, such as aircraft upgrades, modern submarines, and missile systems. Strategic alliances with key global players like the United States, Russia, Israel, and France also facilitate technology collaborations and procurement of sophisticated military equipment.

In addition to the above, a strong push for indigenous development in defence technology is encouraging innovation and growth among domestic companies. The government’s aim to boost defence exports is also opening up avenues for companies to tap into international markets, particularly in regions like the Middle East, Africa, and Southeast Asia. Lastly, India’s space sector, recognised globally for successful missions like the Mars Orbiter Mission and Chandrayaan, has opened up opportunities in satellite manufacturing, launch services, and space exploration.

All of the above are creating a demand for advanced technology and equipment in the country’s manufacturing markets. Aerospace and Defence manufacturers seek technology that offers exceptional quality and precision. Mastercam brings precision and efficiency to the complex parts typical of defence and aerospace manufacturing, with unrivalled metal removal processes for even the toughest aerospace and defence-grade materials.

Success in these domains depends on precision, reliability, and speed. Mastercam provides advanced capabilities and cutting-edge features, including software strategies for complex machining tasks; intelligent toolpaths that effectively target uncut regions; efficient toolpaths tailored to conform to forgings and castings; streamlined 5-axis cutting, trimming, and drilling; specialised motion techniques for extended tool life and decreased cutting time, as well as hybrid manufacturing solutions that integrate additive and subtractive processes.

How can the challenges faced by the aerospace and defence industries, particularly those related to precision machining, be addressed?

Mastercam has been successful for quite some time now in addressing the unique challenges faced by the aerospace and defence industries through continuous innovation and adaptation to evolving needs. One key area of focus is precision machining, which is crucial for aerospace components that must adhere to stringent tolerances. Mastercam’s advanced CAD/CAM modules enable manufacturers to achieve these high levels of accuracy, ensuring that parts meet the exact specifications required for aerospace applications.

Efficiency is another critical aspect, as aerospace and defence projects often involve complex parts and materials that can be costly and time-consuming to machine. Mastercam optimises toolpaths, reducing machining time and minimising material waste. Speed is also significant, especially when meeting tight deadlines in defence contracts or rapidly evolving aerospace projects. Mastercam is designed to streamline the manufacturing process, from initial design to final production, allowing quicker turnaround times without compromising quality.

The aerospace and defence industries also demand high customisation, as each project can have particular requirements. Mastercam’s flexibility allows us to meet these unique needs, whether machining complex geometries, working with specialised materials, or integrating with other manufacturing systems.

The longevity of cutting tools is also a concern in these sectors due to the often prevalent hard-to-machine materials, larger parts, and bulk metal removal. Mastercam addresses this by providing specialised motion strategies that extend tool life, reduce the frequency of tool replacements, and lower production costs. Finally, the comprehensive support structure provided by our global network is crucial for industries that operate globally and require reliable software performance along with trusted and prompt technical support.

How do you ensure quality control in aerospace and defence manufacturing?

Mastercam helps Aerospace and Defence manufacturers uphold quality control and compliance through several key features.

Mastercam’s software offers precise control over machining processes, ensuring that parts are manufactured to specifications. It includes simulation and verification tools that allow users to check the accuracy of toolpaths and ensure that the final product will meet design requirements.

Additionally, the software offers process optimisation tools, aiding in error reduction and enhancing the consistency of manufactured parts. Also, Mastercam facilitates the generation of detailed documentation and reports, which is crucial for adhering to industry standards and regulatory requirements. Furthermore, Mastercam integrates seamlessly with Quality Management Systems (QMS) to ensure that manufacturing processes adhere to established quality standards.

Please discuss the significance of CAD/ CAM and 3D printing in producing complex parts.

CAD/CAM, hybrid manufacturing, and 3D printing play pivotal roles in producing complex parts in the defence and aerospace industries. CAD/CAM technology is essential for creating accurate designs and simulations, ensuring precision in manufacturing processes. This is particularly important in the aerospace and defence sectors, where components must meet strict specifications and tolerances. CAD and CAM are two vital pieces that hold the entire Aerospace and Defence manufacturing process together – in the digital sense.

3D printing, or additive manufacturing, has transformed the aerospace industry by enabling the production of lightweight and complex components, leading to significant cost and efficiency gains. Aerospace companies were among the first to adopt large-scale 3D printing. This technology allows for rapid prototyping, reducing lead times and costs associated with traditional manufacturing methods. It also enables the creation of parts with optimised designs for weight reduction, which is crucial for fuel efficiency and environmental sustainability in aviation.

Hybrid manufacturing, which combines additive and subtractive processes, offers several advantages. It allows for more efficient and flexible production, enabling the creation of parts with intricate geometries that would be challenging to produce with traditional methods. This process streamlines manufacturing, reducing the need for multiple machines and minimising the chances of errors. These technologies enable the production of complex and high-quality components essential for maintaining safety, performance, and competitiveness in these sectors.