The FEEAD project, led by Scintam Engineering Ltd, aims to revolutionise aerospace engine maintenance by developing an innovative solution for the removal of seized fasteners in gas turbine engines. This challenge has long plagued the Maintenance, Repair, and Overhaul (MRO) sector, leading to significant downtime, increased costs, and potential damage to high-value components. At the heart of this project is the adaptation and enhancement of Electrical Discharge Machining (EDM) technology for aerospace applications. EDM, traditionally used in precision manufacturing, offers a non-contact method of material removal that minimises the risk of damage to surrounding components. The FastEDR system applies this technology to the intricate task of removing seized fasteners within complex engine assemblies. The project will focus on three key innovations: 1. Adaptive Fixturing System: A modular fixturing solution will be developed to accommodate various engine types and geometries. 2. Advanced Alignment Verification: Integrating computer vision technology, the project will create a real-time alignment verification system. This will enhance accuracy and reduce reliance on operator skill, opening up complex operations to a wider range of the aerospace technician workforce. 3. Optimised EDM Parameters: The project will involve extensive research to optimise EDM parameters specifically for aerospace materials and conditions, ensuring efficient, safe, and accurate fastener removal across different engine types. These innovations aim to boost efficiency in the MRO sector by: - Reducing fastener removal time from over 8 hours to just 6 minutes - Minimising the risk of damage to high-value engine components - Decreasing engine downtime and associated costs for airlines and MRO providers - Enhancing safety for maintenance technicians - Reducing waste and contributing to more sustainable MRO practices The FEEAD project aligns with the aerospace industry goals of increasing efficiency, reducing environmental impact, and enhancing safety. Successful completion of this project will position the UK at the forefront of aerospace MRO tooling technology, delivering substantial economic benefits through improved MRO efficiency and potential export opportunities. Moreover, by extending the life of engine components and reducing waste, the project contributes to the industry's sustainability objectives. This innovative approach to engine maintenance demonstrates the UK's continued leadership in advanced engineering and aerospace technology.

Remanufacturing is a key resource-efficiency enabler towards UK Net-Zero, saving 9MtCO2e/year by 2050\. It can retain component value, extend functional lifetime, prevent waste and reduce new material inputs. But the process falters at the first barrier -- component disassembly. Seized fasteners result in scrap of potentially remanufactured components at rates of up to 30% and current removal methods cannot meet the speed and accuracy demanded by remanufacturers. Mechanical drilling out of seized fasteners is crude and uneconomical due to the high probability of critical damage and extensive post-processing required, even when automated. By reimagining the electro-discharge machining (EDM) process, ARTES will provide an entirely new method of fastener removal that minimises scrap whilst increasing productivity. Unlike drilling, the damage rates using electro-discharge drilling are extremely low, because the process is contact free and performed at room temperature. Scintam has developed a breakthrough hand-held EDM fastener-removal tool. ARTES builds on this technology, combining Scintam's established technology with machine automation to deliver disruptive new capability that enables widespread adoption of environmentally impactful remanufacturing. This new technology allows unattended remanufacturing of components, swiftly, repeatably, and safely, with minimal setup time. The primary target for ARTES is Tier-1 automotive remanufacturers; initially, remanufacturing will focus on mechanical parts most frequently found on today's automotive passenger vehicles. Significant boost in applicability to high-value components is expected as electric vehicle (EV) remanufacturing matures (battery packs, high-power electric motors, heat pumps). At projected sales volumes, ARTES potentially provides automotive-industry savings of £84Mn and reduction of 197,000 tons-CO2e emissions by 2028 through preventing raw material waste and the need for new material input. Increasing remanufacturing in-lieu of continued over-reliance on long-range global supply chains will consolidate sustainability gains and increase the UK's resilience to rising global supply-chain disruptions and volatility.

Drilling out a bolt in a gas turbine during repair is very skilled -- one slip and a component costing £200k to replace can be destroyed. If the fastener cannot be removed a whole new assembly may be required and the materials will be wasted. The worker in the nuclear decommissioning plant enters the radiation area with a spanner in their hand. They approach the fastener being removed and undo it one quarter turn. They then immediately leave the area -- that's their annual radiation exposure allowance used. 59 more operators will go in and do the same thing before the fastener is released. Having reached the working area of the wind turbine 150m above sea level, the technician finds that the bolt needing removal is seized. To complete the repair, the bolt must be drilled out while the operator is suspended over the sea, pushing against the drill to ensure it cuts through the bolt. These tasks require a faster, safer and customised solution to modernise the process of engineering system maintenance. FastEDR is an advanced tooling platform that effectively dissolves fasteners (nuts, bolts, screw and rivets, etc.), allowing disassembly in safer conditions and with no damage to the components of the product. During use it requires no need to apply mechanical force and produces no environmentally damaging waste. FastEDR can be delivered by robots in areas hostile to humans such as in close proximity to nuclear reactors. Sophisticated software controls and custom designed components mean that FastEDR can be operated by anyone with less than an hour of training. FastEDR allows fastener removal at low safety risk to people and at low cost to customers. We will reduce the environmental impact of UK manufacturing by ensuring that serviceable parts remain in the supply-chain and extending the life of large engineering systems such as gas turbine engines and wind turbines.