This is how the Airbus A350F is built: Tools, Technology, and Industrial Challenges

Airbus is making great strides in the development of the A350F, the cargo version of its successful A350 aircraft family. With final assembly starting this year, the project marks a milestone in the aerospace industry thanks to its technological innovations and optimized processes.

Advanced Engine Pylon Production

One of the key elements of the A350F is its engine pylons, critical components that connect the wings to the engines and withstand extreme temperatures ranging from -50°C to +600°C. Manufactured at the Saint Eloi plant, the pylons for this version have been designed with additional reinforcements to ensure greater durability. Furthermore, a new cowling adapted to these needs has been introduced.

The project has also incorporated an innovative generation of optical fiber that significantly improves the detection of overheating in insulated air ducts. This fiber, thicker and more resistant than conventional ones, minimizes parasitic signals and ensures more reliable operation. The installation of this system was successfully carried out by operators in Saint Eloi, supported by the Electrical Methods Department.

→ STARLUX Airlines Doubles Its Order for Airbus A350F Freighters

Innovative Tools in Toulouse: “Godzilla”

Another highlight in the production of the A350F is “Godzilla,” a unique tool measuring 14 meters in height and weighing 14 tons, designed to facilitate access to the largest cargo door ever installed on the main deck of a civil aircraft. This device, developed in Toulouse, uses motorized wheels guided by QR codes and floor markings, enabling precise and controlled mobility via remote control.

This technology has not only optimized work on the upper fuselage of the aircraft but has also inspired the adaptation of current A350 tools with wheeled robots, speeding up the industrial cycle and ensuring the safety and ergonomics of the operators.

The “Metro”: Advances in Integration and Testing

A crucial milestone achieved by the Toulouse Engineering and Electrical Center was the launch of the first A350F “Metro.” This assembly integrates the main flight test instrumentation systems, allowing functional checks at early stages and reducing the impact on the production schedule.

Weighing approximately 1.8 tons and involving over 4,300 hours of work across engineering and production, the Metro includes an innovative station for flight test engineers. This will facilitate future test campaigns, improving the efficiency of the aircraft’s integration phases.

Industrial Challenges and Successes

Adapting the assembly stations for the A350F also required significant adjustments. The Final Assembly Line (FAL) teams managed to integrate the specific features of this model without disrupting the production of other aircraft. From ergonomic design to the coordination of industrial resources, every step was carefully planned to maximize efficiency.

According to Romain Peyrola, Head of A350 Industrial Operations, “The teams approached each challenge as if it were a marathon, optimizing intervention times to ensure that the production and delivery of the aircraft were not affected.”

The development of the Airbus A350F not only reaffirms Airbus’s leadership in commercial aviation but also highlights the company’s ability to innovate and adapt to the demands of the cargo market.

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