Case Study: Kawasaki Heavy Industries improves flat pattern accuracy with Hexagon FTI FormingSuite

Optimisation of flat pattern shapes for aerospace sheet metal parts

Kawasaki Heavy Industries faced challenges in accurately developing flat pattern blanks for sheet metal parts in its aerospace division, particularly for its bladder forming process. Using conventional geometric unfolding methods and experience-based approaches, the company struggled to predict material elongation and shrinkage, resulting in parts that did not meet precise 3D CAD design requirements. This led to time-consuming development, multiple tryout iterations, and an inability to form complex parts correctly the first time. To overcome this, they turned to vendor Hexagon and its FTI FormingSuite software, which utilizes Inverse Finite Element Method (FEM) technology.

By implementing Hexagon's solution, Kawasaki Heavy Industries created highly accurate developed flat patterns. The Inverse FEM solver within FTI FormingSuite improved the accuracy of the final part's edge by more than three times compared to conventional methods, reducing positional errors from over 3mm to less than 0.12mm. This drastically reduced defects and development time, while also enabling the creation of previously impossible complex shapes. Additionally, the solution allowed for precise hole positioning in the flat pattern, eliminating the need for post-forming drilling jigs and supporting cost-saving hole reference assembly methods.

Kawasaki Heavy Industries