Transforming the Defense Industry: Embracing a New Era of Digital Manufacturing
During a recent online briefing titled “Creating Hardware and Software,” Marcus Wandt, Senior Vice President and Head of Group Strategy and Technology at Saab, articulated the defense industry’s ongoing transformation. This shift is driven by the evolving geopolitical landscape, marked by persistent conflict and rising tensions in Europe, necessitating the expedited delivery of advanced systems.
The Intersection of Tradition and Innovation
Wandt emphasized the convergence of traditional defense companies with startups, fostering a dynamic environment that enhances safety and security. By merging legacy technologies with emerging solutions, Saab aims to transition from a hardware-centric approach to a software-oriented framework. A notable case is the Gripen E avionics system, designed for rapid upgrades—an essential feature in a fast-evolving defense sector.
Key elements of Saab’s strategy include:
- Artificial Intelligence: As a foundational technology, AI plays a pivotal role in enhancing mission capabilities.
- Flexibility: Adapting to swiftly-changing requirements necessitates that hardware evolve to match software’s agility.
Innovating Manufacturing Processes
Axel Bååthe, Head of Saab’s internal innovation hub known as The Rainforest, discussed advancements in fuselage production. He outlined the limitations of traditional tooling and the necessity of a code-defined manufacturing approach. The integration of robotics and additive manufacturing technologies offers the following advantages:
- Algorithm-Driven Design: New manufacturing systems can create complex geometries that would be infeasible through conventional methods.
- Rapid Prototyping: Designs can be translated into 3D printing instructions swiftly, facilitating immediate production adjustments.
Collaborating with Divergent Technologies has enabled Saab to leverage cutting-edge digital manufacturing systems. Divergent has developed the Divergent Adaptive Production System (DAPS), which streamlines the transition from design to production through comprehensive software tools that optimize performance and manufacturability.
Speed and Efficiency in Production
Divergent’s approach enables efficient assembly of structures in ways that traditional techniques cannot. Key features of this process include:
- Speed: The DAPS employs a large-format laser powder bed machine that operates 15 to 30 times faster than conventional printers.
- Adaptability: This allows engineers to swiftly reconfigure production to meet varying design requirements.
Currently, DAPS is utilized across aviation and automotive sectors, producing components with a maximum size of 700x700x835 mm. The joints of these assemblies have been rigorously tested for safety and are validated for critical applications.
Future Developments
Saab’s forthcoming unmanned aerial platform, set to test in 2026, showcases the capabilities of DAPS. The objectives include:
- Dimensions: The fuselage will measure approximately 5 meters long, 1 meter wide, and 60 centimeters high, supporting a payload of around 200 kilograms.
- Component Efficiency: A reduction in parts is projected to exceed 99%, drastically reducing assembly time.
- Sustainability: DAPS manufacturing yields over 90% material waste reduction compared to traditional machining methods.
Bååthe highlighted how new algorithms can optimize structural design to enhance performance while minimizing material use, echoing principles observed in nature. The artificial evolution of designs, likened to Darwin’s concepts, enables real-time adaptations supported by advanced computing and AI.
Addressing Cybersecurity and Regulatory Compliance
As the defense sector advances into these new manufacturing realms, cybersecurity and compliance remain paramount. Data management practices are being established to ensure safety and efficacy, with DAPS also applicable for maintenance and repair operations.
Noteworthy developments in turnaround time have been achieved; for instance, a part mirroring the original’s stiffness and fatigue characteristics could be produced within three days of receiving design specifications.
Looking Ahead
The rapid evolution of digital manufacturing techniques like DAPS positions Saab favorably within the defense sector. This methodology has broader applications beyond fuselage construction, providing opportunities for aerodynamic optimization and enhanced efficiency across various aircraft components.
As Divergent Technologies expands its facilities in the United States, the establishment of a digital factory in Europe by 2028 is also underway. The exploration of this innovative manufacturing landscape promises to yield significant advancements in defense capabilities and sustainability.
As this transformation unfolds, industry professionals will be key players in navigating and implementing these groundbreaking technologies.
