CASE STUDIES AEROSPACE

PRECISION FOR SPACE
VERY CLOSE TO ALL - 1:1 MOCKUP DOCKING PORT
A 1:1 model of a docking port was needed for LiDAR sensor tests. MODELLTECHNIK was able to turn this exciting project into reality.
OUR TASKS
Concept and construction service as well as production of a mobile, transportable, demountable 1:1 model including transport trolley, frame and transport box with maximum precision and dimensions. Project management included.
METHODS AND TECHNOLOGIES USED
Support in product development
Manufacturing of components using additive manufacturing processes (SLS and MLS)
Milled parts including surface coating made of aluminum
Production of laminating tools including 3D printing inserts
Production of fiberglass laminates
Manufacture and customization of bent sheet metal parts
Surface finishing: painting, coating, foiling
Assembly of assemblies
Creation of operating and assembly instructions
Direct delivery with assembly workshop
Customer Benefits
Our customer received complete support from development to the on-site assembly workshop. Our many years of know-how from additive manufacturing, model and mold making came into play. For the mockup, SLS and aluminum parts were manufactured, a laminating tool including different GRP laminates was produced and the surface was finished according to customer specifications. Thank you very much for the pictures from Jena-Optronik GmbH from Mr. Christian Seeling.
258
Machine hours
183
Handwork hours
7
Manufacturing process
5
Materials
„The lifeblood of MODELLTECHNIK is in every prototype. You can feel that in the collaboration and in the results.“
„The lifeblood of MODELLTECHNIK is in every prototype. You can feel that in the collaboration and in the results.“
After just a month of coordination and preparation, production of the docking port mockup could begin. Jena-Optronik was therefore able to carry out the upcoming and necessary sensor tests optimally.
Business Class You Can Touch
A Demonstrator That Makes Design and Innovation Visible
How does the next generation of aircraft seats feel? How do materials, surfaces, and integrated technologies come across in a real spatial environment?
For an innovative aircraft seat, we worked together with the client to construct a high-quality demonstrator. To make the design, materiality, and technological integration tangible in a realistic way, we built this impressive prototype, which not only conveys the design concept but also makes the future user experience tangible.
OUR TASKS
A Demonstrator That Makes Aircraft Cabin Innovation Tangible
METHODS AND TECHNOLOGIES USED
Support in product development
Design
Manufacturing of components using additive manufacturing processes (SLA)
Thermoforming
PMMA Milling
Ureol milling
Lamination
Painting
Component assembly
Customer Benefits
The project was based on the Class-A surface data provided by the client, along with design specifications defining the different color and material variants of the components.
The actual seat cushion was integrated into the model by the client, allowing design and functionality to be combined seamlessly.
To optimally achieve the required design quality, structural stability, and surface finish, a carefully selected combination of materials and technologies was used. A thermoformed PMMA component, finished with high-quality paint and photo printing, realistically simulates an integrated display.
Visible design components were produced using the SLA process and were partially laser-processed to achieve particularly smooth surfaces and fine details. In addition, CNC-milled components made from PMMA and Ureol were manufactured, painted, and partially laminated, creating a material appearance close to series production.
Painted walnut elements provide additional design accents and underline the premium character of modern aircraft cabins.
471
Machine hours
659
Handwork hours
5
Manufacturing process
4
Materials
„We are impressed by the outstanding quality and attention to detail. MODELLTECHNIK was the perfect partner and specialist at every stage of the project.“
„We are impressed by the outstanding quality and attention to detail. MODELLTECHNIK was the perfect partner and specialist at every stage of the project.“
MODELLTECHNIK carried out the detailed engineering and took responsibility for the complete manufacturing and assembly of all visible seat components, combining them into a high-quality demonstration model. The goal was to represent the design as close to a production version as possible, while achieving exceptional presentation quality.