Special Purpose Production

Defense and Aerospace

Special Purpose Production and Assembly Systems

We design integrated automation cells for the non-standard assembly and specific production needs of the defense and aerospace industries.

Our Related Defense Solutions

ATAK Project Custom Helmet Production System (CNC Cell)

This is our custom 5-axis CNC machining cell product with optical scanner integration, enabling the machining of helmet cheek and pad slots on a CNC machine with micron-level precision based on 3D scan data of the pilot's head for Aselsan ATAK Helicopter pilot helmets. It ensures perfect alignment of the helmet and visor optical axes.

Solved Problems and Challenges

Smart helmets produced for ATAK Helicopter pilots must match the head anatomy at the micrometer level. The slightest alignment error causes the night vision and targeting displays (HUD) on the helmet to deviate from the pilot's eye axis, leading to headaches and targeting deviations in the air. The developed 5-axis CNC robotic system carves the pads with sub-millimeter precision according to the pilot's head scan data.

Theoretical Background and Study

For the production of pilot helmets, a point cloud consisting of millions of coordinate data is collected from the pilot's head using a 3D optical laser scanner. Our transformation algorithms instantly convert this raw point cloud into smooth 3D surface mesh (CAD) models. This surface data is transferred to the 5-axis CNC unit, ensuring that the helmet pad slots and cheek pads are carved to exact tolerances according to the pilot's head structure.

Force-Feedback UAV Wing Assembly Manipulators

This is our smart robotic assembly platform product that aligns the carbon-composite wing components of ANKA and Aksungur unmanned aerial vehicles produced by TAI (TUSAŞ) to the fuselage with sub-millimeter precision and zeroes out fiber tension during assembly. The system's axial drive and safety control are managed by a Siemens S7-1500 PLC control unit.

Solved Problems and Challenges

During the positioning of massive carbon-composite wing components of unmanned aerial vehicles (ANKA, Aksungur, etc.) on the fuselage assembly line, conventional manipulators cause mechanical strains (contractions). These instantaneous stresses on composite fibers create capillary micro-cracks in carbon structures, shortening the fuselage life during flight. Thanks to the developed force-feedback (load-cell integrated) closed-loop control system, assembly is performed safely with zero mechanical contraction.

Theoretical Background and Study

In our carbon wing assembly manipulators, instantaneous torque/force limitation is applied in addition to position control. Precision load cells located at the joint points of the manipulator continuously measure the force exerted on the wing during assembly. When an axial positioning error is detected, closed-loop torque limiting cycles are activated, cutting off engine power or making position corrections to guarantee zero contraction on the wing.

Product Specifications and Performance Standards

CNC Scanning and Machining Precision

5-Axis CNC / ±5 µm Precision

Organic surface machining accuracy at the 5-micrometer level provided by the CNC machine while carving the pad slots according to the pilot head mesh data.

Manipulator Force Tracking Tolerance

Closed-Loop Force-Feedback / <10 N Tolerance

Closed-loop load cell feedback response that prevents fiber damage by keeping the contraction force that could burden the carbon structure during UAV wing assembly below the limit of 10 Newtons (approximately 1 kg force).

PLC and Communication Infrastructure

Siemens S7-1500 / PROFINET IRT

Siemens S7-1500 PLC and PROFINET IRT communication architecture providing real-time and deterministic 1 ms cycle time between load cells, servo drives, and safety interlocks.

Ideal Application Areas

Custom Smart Military Equipment Production: CNC production of pilot helmets, sighting devices, and wearable military body armor with 3D optical measurement.

Composite Aerospace Structures Assembly: Load-cell robotic manipulators preventing contraction in UAV, helicopter, and aircraft fuselage/wing assembly lines.

Tailor-Made Robotic Cells: High-precision 3D machining, alignment, and automation cells that cannot be realized with standard industrial machines.