FACC has delivered to the Airbus Wing assembly line in Broughton, England the first production-standard 'Outboard Flap' ship-set for the Airbus A321. Here, it will be integrated into the wing and then shipped to the Airbus plants in Hamburg for installation into the aircraft. Flaps are moveable wing components mounted on the trailing edges of the wings to raise the lift during takeoff and reduce the speed during landing.

In April 2012 Airbus awarded FACC the contract to manufacture the Outboard Flaps for the A321; and based on their extensive experience in the development and manufacture of wing components, FACC introduced a new manufacturing concept that ensures innovative technologies, automated production processes and optimized product specifications.

Walter Stephan, the FACC CEO stated: “This is the first production component of any kind to be shipped from our facility – in addition - this first unit was built at our new 'state-of-the art production line' using an automated composite fabrication technology and the technical expertise of our employees.”

When we are at full capacity, approximately 120 employees will be employed on this program. “That thanks to the strong demand for A321 aircraft, this work package is a major contribution to future revenue growth of FACC," added Walter Stephan. Depending on the market demand, the contract foresees approximately 770 Outboard Flap shipments being delivered within the next 5 years.

Investments in Higher Automation

With the production launch of the Outboard Flaps, FACC has made an important step forward in production technology by implementing the "Automated Tape Laying (ATL)" which is consequently used in processing composites for the aerospace industry. Our ultra-modern prepreg lay-up machine enables an automated application of the carbon fiber layers; thus replacing a time-consuming and costly manual lay-up process. In addition, a new Hot De-Bulking System has been installed in order to produce a 'wrinkle free prepreg' for the automated laid-prepreg-laminate process over a narrow radius.

With our investments in the ATL and Hot De-Bulking System, FACC continues with its strategy in the expansion of technology and quality leadership. By doing so we have substantially increased our production capabilities to accommodate the continuing - and ever growing demand - for composite components in aircraft construction. The company is now able to provide a fully automated manufacture of a wide range of components to the highest quality and a corresponding increase in productivity. Thus, FACC has achieved a significant technological leap in the automation of composite components production, compared to conventional predominantly manual processing.