Upcycled products that reflect the spirit of the craftspeople and the atmosphere of the aircraft production floor

In our daily work, we cut test metal and resin specimens, which are used to evaluate the mechanical properties and strength of materials, components, and products. In that sense, cutting and fabricating various shapes and rare materials are some of our daily tasks.

To cut a workpiece accurately, we need to understand its material and shape, secure it firmly so that it does not move, and select the optimal cutting method. Precision measurement and tool manufacturing are our strengths. First, we scanned the 3D shape of the blade, converted it into a 3D model using CAD (Computer Aided Design), and then derived the optimal cutting process.

We tried wire cutting (wire electrical discharge machining, a method of cutting a workpiece while melting it by passing an electric current through a wire such as brass), which we use when cutting super-hard materials. At first, the electricity would not flow as we hoped and we could not cut it. When we looked into it, we found that there was a coating around the workpiece. After peeling it off, we were able to cut it, but even if the outside was fine, the wire would stop at the hollow part inside. In the past 20 years or so that I have been involved in machining, I have rarely been unable to cut something, so I thought maybe this time I had really met my match.

When we received the blade from ANA, we did not know the material, nor how it was structured inside. Nabeya Manufacturing is a group of experts who can measure anything, from large facilities such as plants to small parts. We immediately consulted with Nabeya Manufacturing, knowing that if we had something challenging, they would be able to advise. 

Nabeya Manufacturing is involved in the machining and subassembly of parts, as well as the manufacture, modification, and repair of tools. We have been asking them to manufacture parts and tools for all types of civilian and defense aircraft. They are also strong in high-precision measurement, such as product measurement and regular inspection using 3D laser measurement. I think you can feel the spirit of Nabeya Manufacturing's machining technology and pursuit of precision from the products we have created.

For this product, we used the same equipment to fabricate sheet metal as we do for manufacturing aircraft parts, and we implemented assembly using the same assembly technology as for aircraft. Thanks to Tenryu Aero Component's technical capabilities, the product conveys the manufacturing technology of aircraft from the aspects of both aircraft parts and the assembly process.

Our company is mainly responsible for the manufacturing of components that become part of the aircraft, which are usually not visible. I was very interested in this project, because it was intended to create products that users can see and touch for themselves. It was a new field for us, but I think we were able to make use of our high-quality manufacturing skills in aircraft manufacturing and the technical capabilities that we have fostered at our company. I hope that people will experience and appreciate these products, each of which were created with the same technology as real aircraft manufacturing.

The business card holder's lid also demonstrates Tenryu Aero Component's attention to detail. The lid is movable and is designed to look like the landing gear control lever in the cockpit. The initial order was simply to make it openable, but Tenryu Aero Component proposed adding a touch of refinement to how it feels to open and close it.

The material used for this product is typically hidden by paint. However, in this product, we were able to capture a moment in the material's journey to becoming an aircraft. The product would never be good if it were rough cut, but neither would it be good if it were over-finished. I hope you can feel this kind of exquisite care we took during the manufacturing process. Also, the surface was originally shiny, but we deliberately ran it through a deburring machine and matted it, considering that users would invariably scratch it over time. This kind of machining results in different expressions for each piece.

Through this project, we have developed a new perspective. It is a wonderful thing that materials that would normally be discarded can be reused in this way to create new products. We have also started to look for ideas for new products even for things that, up until now, have mostly gone unnoticed by asking ourselves, “What kind of product could we make this material into?”

I work in this industry because I love manufacturing. I am very proud that our technology was used in this product. In the past, we mainly focused on accurately processing products according to the drawings we received. However, this time, we were able to participate in the product development, too, which was a great experience. I believe that this project will also lead to an increase in employee motivation. In addition, by using scrap and surplus materials, we have added value to what would otherwise be discarded, which is also a contribution to our Sustainable Development Goals. I am proud to be a part of such a project.

It is rare for the general public to be able to experience the technology of an aircraft directly, so as a craftsperson, I worked even more carefully and with all my heart, envisioning the person who will be using this object, and how they will receive what I was creating. In addition, I learned about technologies that I did not know in my interaction with Nabeya Manufacturing, so I would like to stay in touch with them. This time, we mainly dealt with aluminum alloys, but if we were to make another product, I would like to take on the challenge of using different materials, as well.

I would be happy if people from all walks of life would become more interested in aircraft by encountering a product born from aircraft manufacturing technology. Now that we have passed through the COVID-19 pandemic, it is time to strengthen employment and technology. We are working together as a team to see how efficiently we can make high-quality products in a short period of time. We will continue to explore how to hand down our high manufacturing technology to the next generation.

I think the unique appeal of this industry is the immense scale of an aircraft, which you can sense even in the manufacturing of tools. It is also a world of digital technologies such as the 3D measurement tools that we used with the engine blade key chain. In that sense, as well, I think people will find our work quite intriguing.

The making of aircraft involves complex issues such as how to create more efficiently, how to ensure the process flows better, and how to increase productivity in small-lot, high-variety manufacturing. We are working with Kawasaki and other partners to address and solve these complex issues. I believe we have an environment where people can enjoy manufacturing through their interactions with various people. When people experience firsthand the upcycled products we make with aircraft manufacturing technology and aviation materials (scrap and surplus materials), which they do not usually have the opportunity to touch, it will increase their interest in aircraft manufacturing, which, in turn, will help the aircraft industry to thrive.