Project Wingcopter
Case Study
Aerospace Machining for Wingcopter GmbH
Executive Snapshot
Customer: Wingcopter GmbH – German developer of long-range electric delivery drones
Result: ARRTSM delivered a fully autonomous digital production cell including automation, noise reduction cabin and chip removal system, reducing cycle time from 2 days to 2 hours per drone fuselage (–93%), enabling Wingcopter to scale from craft-based builds to industrial throughput in a single shift
Role: End-to-end design, build, and CE-certified commissioning of an AI-driven, “lights-out” machining cell.
The Challenge
Wingcopter’s cutting-edge eVTOL drone features a composite foam fuselage requiring high-precision 5-axis milling and hand finishing. The legacy process consumed 16 labor-hours per unit, with a 2-day turnaround—restricting production to just 1.5 drones per week.
With demand from African medical logistics and German parcel trials growing rapidly, Wingcopter needed:
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A dust-controlled, CE-certified robotic cell
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Precision milling with <0.2 mm tolerance
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4× higher monthly throughput
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Reduced reliance on skilled CNC labor
ARRTSM Solution
| Aspect | Implementation |
|---|---|
| Factory Model | Fully autonomous CNC cell with UGV-ready material interface |
| Parts Produced | CNC-milled drone fuselage halves, load-bearing foam ribs |
| Materials | Carbon-reinforced CNC foam, CFRP skins |
| Key Hardware | 1× KUKA KR240 R2900 Prime robot on 7 m linear rail; Siemens Sinumerik-840D controller; smart gripper & vacuum handling system |
| Dust & Safety | Class-II acoustic chamber, ATEX dust extraction, CE-certified light curtains |
| Commissioning Time | 14 weeks from order to qualified output |
| Programming | Full-cycle digital twin (Unreal Engine™); zero pendant teaching required |
Lessons Learned & What’s Next
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Digital twin simulation eliminated weeks of on-site commissioning
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Reusable software framework now powers Wingcopter’s next-gen “198” cargo drone line
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Next upgrades:
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Dual-robot synchronized milling to further reduce cycle time
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In-line ultrasonic NDT
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Centralized control by ARRTSM’s 3D-based path optimization platform
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Join the ranks of satisfied companies that have witnessed the transformative power of our wood solutions. Experience the efficiency, precision, and quality that ARRTSM brings to the woodworking industry. Contact us today to explore how our advanced robotics technology can elevate your woodworking processes and drive your company’s success.
