Dispensing Innovations For Advanced Air Mobility

Innovations in aerospace technology, a stronger commercial focus on decarbonization and the evolution of electric mobility are accelerating the momentum of advanced air mobility. This progress is particularly evident in the development of electric vertical takeoff and landing aircraft (eVTOLs). These innovations are gaining traction across various applications, including inter-city transportation, emergency and medical services and private personal aerial vehicles. One company, recognizing the increasing adoption of eVTOLs, has developed its own solutions for this technology. To simplify their assembly process and ensure manufacturing efficiency, this new aerospace market entrant sought a custom automated dispensing solution from GP Reeves.

The Problem

The eVTOL segment is still in its infancy. Manufacturers are currently deploying prototypes and must develop assembly processes without precedent production examples. While this lack of comparison poses challenges, it also presents significant opportunities for success. One manufacturer sought assistance with their material delivery and wanted a solution that would integrate seamlessly with their existing production automation concepts. They chose GP Reeves for our willingness to customize automated precision systems to meet unique and challenging needs. GP Reeves collaborated closely with the team, considering each part’s aspects, material properties, surface area, and environmental conditions to configure the optimal solution.

eVOTL Thermal Plate Inverter 

One of the systems GP Reeves developed was specifically tailored to meet the requirements of the inverter thermal plate components in the eVTOL motor. We successfully designed and programmed a robotic dispensing cell capable of adapting to the evolving geometry of the part throughout its construction. This system ensured precise material dispensing, even as the shape of the thermal plate changed during development.

The process began with the base plate component entering the automation cell and being secured to a custom nest system. A 3D vision camera then verified the part and its position on the nest. Once the system identified the part and the surface areas requiring material application, a robot swapped the camera for a custom dispense head specifically designed for that part.

This application involved dispensing multiple materials, including various adhesives and thermally conductive pastes, adding an extra layer of complexity. The robot adapted to the different material requirements by selecting the appropriate dispense head from several connected to distinct dispense systems. These systems, equipped with pumps and servo dispensers, efficiently transferred the required material from its original container to the dispense head.

Following the precise application of the material, the robot re-engaged the camera to verify the material had been accurately dispensed onto the components. Once confirmed, the next layer of the thermal plate was loaded, and the robot recognized the updated topography of the plate. It then repeated the dispensing process, applying material to the necessary areas of the new part.

Each layer of the thermal plate required precise material beads at specific locations, with varying volumes. Our system was engineered to accommodate these unique requirements, ensuring accuracy, efficiency, and repeatability. This verify-dispense-verify process was repeated for each layer until all layers of the thermal plate received the necessary material. Upon completion, the finished part exited the cell, and a new base plate entered the system.

Adhering Pouch Cell Layers 

With vision-based verification and a consistent material supply, the robot precisely dispensed the UV-cured adhesive in controlled beads across designated areas of the pouch cell layers. Customized controls ensured accurate material application on each part, providing the customer with confidence in the quality and consistency of the process. After the dispensing cycle for a given layer was completed, the automated system would load the next layer of the battery module and repeat the procedure. This process continued layer by layer until the entire module was sealed, after which the completed module would exit the custom nest, and the system would prepare for the next single layer.

Thanks to the system’s exceptional precision, concerns about improper material placement were minimized. The system’s rapid cycle times and custom-built components allowed for an efficient and streamlined assembly process of the eVTOL’s energy storage units.

Electric Propulsion Assembly 

Similar to the previous thermal plate project, GP Reeves developed a robotic system that significantly advanced the aerospace developer’s assembly process. We engineered a custom nest designed to seamlessly interface with the customer’s pallet and parts. The robot, programmed by our team, initiated the dispensing process by utilizing a 3D vision camera to accurately assess the electric motor part’s position on the nest. After verifying the part and its specific requirements, the robot swapped the camera for a plasma treatment gun to apply plasma to the part. This treatment was included due to its beneficial effects on electrical components, particularly in enhancing material bonding.

Following the plasma treatment of the stator surfaces, the robot returned the plasma gun and transitioned to the dispensing phase. Given the range of materials required for this assembly, we developed separate dispensing systems equipped with dual pumps and servo-driven positive displacement dispensers, ensuring a reliable and consistent supply of each material when needed.

Based on the initial camera verification, the robot selected the appropriate dispensing head and tip, confirming that it matched the part’s specific material requirements. This meticulous process ensured both precision and efficiency in material application.

Once all verifications were complete, the system dispensed precise beads of material in the required volumes and patterns to the designated areas of the propulsion component. After the material was applied, the robot replaced the dispense head with the camera to confirm correct placement and positioning. Upon successful confirmation of accurate material delivery, the next component of the electric motor was introduced to the cell, and the process was repeated. This cycle continued until all components were processed and the construction of the electric propulsion system was completed. The module then advanced to the next automation cell, and the dispensing cell began work on the next base part.

Final Results

The custom solutions provided by GP Reeves allowed the aerospace developer to significantly enhanced assembly efficiency, improved material precision, and minimized production downtime. Our automated systems offered a dependable method for delivering specialized materials to various components, successfully addressing challenges such as the use of unique materials, complex multi-stage constructions, and compliance with strict government regulations. As the air mobility sector continues to evolve and eVTOL technology gains momentum, GP Reeves is proud to support the industry’s diverse assembly processes with our innovative dispensing systems.