Master complex Aerospace Assembly with Real-Time Precision
In aerospace manufacturing, precision is non-negotiable. Large structures, complex geometries and strict certification requirements make every assembly step critical. nexonar enables Real-Time Location Tracking of tools and operations, ensuring process compliance, quality and full traceability across aerospace production.
By guiding operators and validating each step in real time, nexonar helps prevent errors such as missing screws, incorrect tightening sequences or rework, while improving overall productivity, safety, and compliance.
Typical customer challenges
Wrong operation at the wrong location
Large aerostructures such as fuselage sections, wings or frames make it difficult to ensure that every drilling or tightening operation is executed at the correct position. Even small deviations can lead to rework or compliance risks.
Incorrect tool or process parameters
In aerospace assembly, similar positions may require different torque, angle or drilling parameters. Manual parameter selection increases the risk of human error and can result in structural issues.
Limited feedback from tools
Many aerospace tools, especially pneumatic or manual tools, do not provide real-time feedback. Errors are often only detected during inspection or rework stages.
High complexity in aerospace processes
Multiple variants, mixed sequences and front/back operations increase operator complexity and training effort in aerospace manufacturing.
Traceability and compliance requirements
Aerospace production requires full traceability of each assembly step. Manual documentation is time-consuming and prone to errors, increasing compliance risks.
How can nexonar solve these challenges?
Real-time tool tracking in aerospace
nexonar tracks the exact XYZ position of tools in real time, ensuring that every operation is executed at the correct location across large aerostructures. Camera clustering ensures position verification across large assemblies.
Automatic parameter control
The system automatically selects the correct tightening or drilling parameters based on the tool position. Incorrect settings are blocked, ensuring each operation follows defined aerospace process specification.
Smart tool enablement
nexonar transforms simple tools into smart tools by monitoring process start, progress and completion in real time, even for pneumatic tools without native feedback. It helps to confirm each action is performed at the correct location.
Operator guidance and error prevention
Visual on-screen or projection guidance systems support operators step by step, indicating the correct position and sequence while providing real-time OK/NOK feedback.
Full digital traceability
Every operation is recorded by Demeter with position data, torque values and process status. This creates a complete digital record for aerospace traceability and compliance.
nexonar in Aerospace Assembly
In aerospace assembly, whether for OEMs working on large aerostructures or suppliers producing avionics components, even small deviations can lead to costly rework, compliance issues, or potential safety implications. nexonar helps reduce these risks by ensuring that critical operations are performed at the right location, in real time, while providing full operation-level traceability for processes such as drilling, fastening, and quality checks.
Jerome Couroye
Global Business Manager Aerospace
Advantages of the nexonar solution at a glance
Rework optimization & control
Process monitoring
Error-proofing solutions
Digital Transformation
Your questions about nexonar in aerospace assembly answered
What is RTLS in aerospace manufacturing?
A Real-Time Location System (RTLS) in aerospace manufacturing is a technology used to track the exact position of tools and assembly operations in real time. It ensures that each task - such as drilling or tightening—is performed at the correct location and in the correct sequence.
How does tool tracking work in aerospace assembly?
Tool tracking in aerospace uses sensors and cameras to monitor the position and movement of tools during the assembly process. With nexonar, the system tracks tools in real time and verifies that each operation is executed at the correct position with the correct parameters.
Why is RTLS important for aerostructure assembly?
Aerostructure assembly involves large and complex components such as fuselage sections, wings and frames. RTLS ensures precision by guiding operators, preventing errors and enabling real-time validation of every assembly step, which is critical for safety and compliance.
How does RTLS improve quality in aerospace manufacturing?
RTLS improves quality by preventing incorrect operations, such as wrong tightening sequences or drilling at incorrect positions. It ensures that every process step is executed correctly the first time, reducing rework and ensuring consistent product quality.
Can RTLS provide traceability in aerospace production?
Yes, RTLS systems like nexonar provide full traceability by capturing process data such as tool position, torque values and OK/NOK results. This creates a complete digital record of all assembly operations, supporting audits and certification requirements.
Does RTLS work with pneumatic or manual tools?
Yes, nexonar can integrate with pneumatic and manual tools by adding position tracking and process monitoring. This enables real-time feedback and validation even for tools that do not have built-in intelligence.
How does RTLS support operators in aerospace assembly?
RTLS systems provide visual guidance and real-time feedback to operators. They show the correct position, sequence and status of each task, reducing complexity and simplifying training in highly demanding aerospace environments.
What types of aerospace applications can benefit from RTLS?
RTLS can be used across various aerospace applications, including:
Aerostructure assembly (fuselage, wings, frames)
Drilling and tightening operations
Engine and component assembly
Complex mixed-sequence assembly processes
What are the main benefits of RTLS in aerospace?
Key benefits include:
Improved quality and reduced rework
Increased productivity and shorter cycle times
Full traceability and compliance
Reduced operator errors
Better process transparency
Is RTLS scalable for large aerospace assemblies?
Yes, RTLS solutions like nexonar are designed to scale across large production areas. Multiple cameras and tracking systems can be combined to cover complex aerostructures and enable precise tracking across the entire workspace.
