Are you about to ramp up UAS/sUAS production? FLEXYS accelerates the transition from prototypes and manual small-series production to large-scale industrial production: flexibly, scalably and with assured quality.
Scalable
from assembly of individual units to full automation
Modular and adaptable to different versions –
making new models, sizes and designs possible
Poka-yoke quality assurance and traceability
of each component
Integrated end-of-line tests
are standardised, reproducible and documented
01
Whether they produce FPV drones, loitering munitions or ISR sUAS, manufacturers are faced with the challenge of rapidly increasing their production numbers without compromising on reliability or quality. In the future, assembly, payload integration and incorporating command-and-control components must be efficient, reproducible and scalable. FLEXYS provides the perfect automation solutions to meet these challenges with ease.
02
Modularity –
Retrofittable and replaceable for new models and versions, open interfaces (open architecture).
Scalability –
From assembly of individual units to partial automation to industrial-scale production lines.
Quality assurance –
Inline tests, edge computing-supported tests.
Time-to-ramp –
Faster transition to high-volume production.
03
Using methods such as Chaku-Chaku, SMED, and Poka Yoke, the manufacturing of ISR and VTOL platforms becomes process-safe, setup-time-efficient, and operator-friendly. This enables the assembly of mission-critical systems with maximum reliability and efficiency.
04
From the first component to the final test run, FLEXYS integrates all the central steps in UAS production into a flexible, consistent manufacturing system. The result is efficient procedures, reduction in errors, shorter throughput times and maximum quality.
MANUAL ASSEMBLY ASSIST –
Human-in-the-loop ergonomic equipment, visual guidance for workers and ESD protection ensure smooth manual assembly
INSTALLING SCREWS –
Automated screw installation processes including screw feed and torque control
INSTALLING RIVETS –
Time-saving, reliable riveting systems for stable structural connections
SOLDERING –
Reproducible soldering processes with temperature profile monitoring for electronics and avionics modules
GLUING –
Precise application and curing for weight-bearing and functionally critical adhesive connections
CLAMPING –
Quick, fail-safe locking of plastic components
CLINCHING –
Force/displacement-monitored clinching for permanently load-bearing mechanical structural assembly, such as for airframe and fuselage
CLIPPING/LATCHING –
Monitored clipping/latching for stable, flawless connections
WELDING –
Laser and ultrasonic welding methods for robust, precise structures for lightweight construction and ruggedised components
MARKING –
Laser marking for traceability and interoperability
PROGRAMMING –
Automated reflashing and parametrisation of the controller/software
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Manual assembly –
Work performed by humans, modular equipment, point-of-use supply
Partial automation –
Human workers combined with robotic support
Full automation –
Synchronised UAS assembly lines, automated flow of material, persistent production capability
06
FLEXYS supports open systems architecture – compatible with common MES/ERP interfaces (OPC UA, REST). This allows production data from drone assembly, payload integration and command-and-control modules to be tracked at all times.
07
Our systems meet CE and security standards, account for EW-contested environments and comply with ESD/EMC requirements. Our resilient processes ensure manufacturing quality while meeting the most demanding requirements.
FLEXYS is the flexible automation solution from PPS and combines decades of experience automating complex manufacturing processes in the automotive industry with the requirements in the defence and UAS industry: modularity, reliability, and scalability.
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