Hole quality prediction
Diameter, roundness, cylindricity and burr formation predicted in process from spindle telemetry, acoustic signature and vision.
Capability, station by station
The full capability surface of the platform, grouped the way an assembly line actually works — sense, align, drill, fasten, seal, join, move, verify.
| Segment | Share |
|---|---|
| Drilling & fastening | 31% |
| Inspection & FOD | 24% |
| Align & shim | 19% |
| Line & handling | 14% |
| Seal & join | 12% |
Perception at station speed
Vision and in-process metrology fuse into one as-built state. Nothing is sampled; everything is measured.
Countersink flushness
Depth and flushness measured against the local surface normal, not a nominal plane — the difference that catches a proud fastener.
Fastener seating & torque
Interference fit, seating and installed torque verified per fastener code, with the installation trace bound to the hole record.
Edge distance & pitch
Every hole checked against edge distance and pitch requirements for its structural zone before the fastener goes in.
FOD detection
Swarf, chips, tooling and debris detected inside closed structures — the class of escape a flashlight sweep is designed to miss.
Interlaminar gap sensing
Gaps between stacked metallic and composite layers sensed during one-up assembly, driving the decision to peel or proceed.
Fit is predicted, not discovered
Gap prediction MAE
0.031 mm
▼ -58% decrease
Fit-up iterations
1.06
▼ -69% decrease
Alignment cycle
22 min
▼ -63% decrease
Shim machining first-pass
98.4%
▲ +22% increase
Metrology fusion
Laser tracker, photogrammetry, iGPS and scanner clouds registered into one coordinate frame with automatic outlier rejection.
Predictive gap field
The full gap surface across a join predicted before mate, not sampled at a handful of feeler-gauge points.
Shim geometry generation
Machined or liquid shim geometry generated directly from the predicted field and sent to the shim cell.
Tolerance stack-up
Stack-up modelled across the whole join sequence, so an in-tolerance part in the wrong order is caught before mate.
Adaptive control, per stack-up and per fastener code
Adaptive feed & speed
Feed and spindle speed modulated through the stack in real time against burr risk, delamination risk and thermal load.
One-up assembly control
Drill, deburr decision and fasten in one pass where the gap and clamp-up allow it — and a hard stop where they do not.
Countersink depth control
Depth driven against the sensed local surface, holding flushness through skin thickness variation and curvature.
Interference & torque
Rivet and bolt installation controlled to the interference and torque band for that fastener code and structural zone.
| Countersink flushness deviation (mm) | Fasteners | Within spec |
|---|---|---|
| −0.06 mm | 12 | No |
| −0.04 mm | 84 | Yes |
| −0.02 mm | 612 | Yes |
| 0.00 mm | 1840 | Yes |
| +0.02 mm | 1420 | Yes |
| +0.04 mm | 384 | Yes |
| +0.06 mm | 61 | Yes |
| +0.08 mm | 8 | No |
Sequencing that protects the stack-up
Sealant bead control
Bead width, height and fillet profile controlled against substrate geometry, with in-line profile inspection.
Cure-window management
Application-to-mate windows tracked per sealant batch, with the line held rather than the joint compromised.
Join sequencing
Mate, fasten and seal ordered so that tolerance stack-up and cure chemistry both stay inside their envelopes.
Wing-body & fuselage join
Purpose-built sequencing for the highest-consequence joins on the airframe, gated by the twin at every step.
Sealant waste tracking
Dispense volume reconciled against joint geometry, cutting both waste and the rework a starved bead causes.
Faying-surface verification
Surface preparation and sealant coverage verified before mate — after mate, nobody can see it again.
The line and the machines that carry the structure
Station balancing
Content rebalanced against real cycle times every shift, on both moving and pulse lines.
Takt-breach prediction
A position that will miss takt is flagged hours ahead, with the resequencing that avoids it.
Travelled-work control
Work pushed downstream is the most expensive work in the factory. The agent minimises it explicitly.
Crawler & AGV control
Flex-track crawlers, mobile platforms and AGVs positioned and supervised with structural-load awareness.
Crane & positioner handling
Large-structure lifts planned and supervised, with fail-safe stop wired into every actuator.
Collision & envelope guarding
Machine, structure and human envelopes checked continuously against the live as-built model.
Every hole measured, not one in four
Hole diameter, countersink flushness, fastener seating, edge distance, gap and FOD are sensed in process — so a non-conformance is caught at the station that created it.
| Hole diameter (mm) | Holes | Within spec |
|---|---|---|
| 6.32 mm | 3 | No |
| 6.33 mm | 22 | Yes |
| 6.34 mm | 168 | Yes |
| 6.35 mm | 940 | Yes |
| 6.36 mm | 2410 | Yes |
| 6.37 mm | 2280 | Yes |
| 6.38 mm | 810 | Yes |
| 6.39 mm | 132 | Yes |
| 6.40 mm | 19 | Yes |
| 6.41 mm | 2 | No |
| Segment | Share |
|---|---|
| Hole quality / burr | 34.2% |
| Countersink flushness | 21.6% |
| Gap & shim fit | 18.4% |
| Fastener seating / torque | 13.1% |
| Sealant profile | 7.9% |
| FOD | 4.8% |
Where the line is losing its takt, four hours before it does
Station balancing is a continuous optimisation, not a quarterly study. Rivetira predicts the breach and proposes the resequencing that avoids it.
| Station | Shift A | Shift B | Shift C | Weekend |
|---|---|---|---|---|
| FA-01 Section join | 98.4% | 96.2% | 94.1% | 91.8% |
| FA-02 Wing-body | 97.1% | 95.4% | 93.2% | 90.4% |
| FA-03 Empennage | 99.2% | 98.1% | 96.4% | 94.2% |
| FA-04 Systems | 95.8% | 94.2% | 92.6% | 89.9% |
| FA-05 Final | 96.9% | 96.1% | 95.0% | 92.7% |
Every station, every structure, one record
Sort any column. The same table backs the audit export an airworthiness engineer hands to a regulator.
| FA-01 · Fuselage section join | Section 41/43 | 0.041 mm | 18 h | ||
|---|---|---|---|---|---|
| FA-02 · Wing-body join | Wing box | 0.062 mm | 31 h | ||
| FA-03 · Empennage attach | Vertical/horizontal | 0.028 mm | 9 h | ||
| FA-04 · Systems installation | Hydraulics/electrical | 0.055 mm | 12 h | ||
| FA-05 · Final assembly | Interiors/doors | 0.037 mm | 6 h | ||
| WG-11 · Wing skin-to-spar | Lower skin | 0.033 mm | 22 h | ||
| WG-12 · Wing skin-to-spar | Upper skin | 0.048 mm | 26 h | ||
| FS-21 · Fuselage panel | Barrel section | 0.030 mm | 11 h |
Hit the fit before the join
Every airframe diverges from CAD the moment the first hole is drilled. The as-built twin models that divergence — fit, gap, shim, drilling and structural conformance — and simulates the join before a single fastener is installed.
- Simulates fit, gap field and shim geometry against the real as-built structure, not the as-designed model
- Gates every autonomy promotion: an agent only takes a step in the plant after it takes it in the twin
- Predicts tolerance stack-up across the whole join sequence, not point by point
- Replays any historical join for root-cause analysis and airworthiness investigation
| Structure | Twin prediction | Measured as-built |
|---|---|---|
| Section 41 | 0.31 mm | 0.34 mm |
| Section 43 | 0.44 mm | 0.41 mm |
| Section 44 | 0.28 mm | 0.30 mm |
| Wing box L | 0.52 mm | 0.55 mm |
| Wing box R | 0.49 mm | 0.47 mm |
| Empennage | 0.22 mm | 0.24 mm |
Reads and writes back to the machines you already own
Rivetira is not a rip-and-replace. It connects to the drilling machines, crawlers, trackers, shim cells, sealant robots and MES already on your floor over APIs and OT protocols.
Drilling & fastening
- Flex-track crawlers
- Gantry drilling machines
- C-frame riveters
- Automated fastening cells
- Hand-fed ADUs
Metrology
- Laser trackers
- Photogrammetry rigs
- Structured-light scanners
- iGPS / indoor GPS
- Articulated arm CMMs
Shimming & sealing
- 5-axis shim machining
- Liquid shim dispense
- Sealant robots
- Cure monitoring
- Bead inspection
Factory systems
- Assembly MES
- PLM / as-designed models
- ERP work orders
- Quality / NCR systems
- Historians & OPC UA
OPC UA, MTConnect, MQTT, ROS 2, REST and file-drop connectors. Read-only shadow mode first; write-back enabled only after twin validation.
Built for programs that cannot leak and cannot fail
Airframe geometry is among the most protected IP in manufacturing, and much of it is export-controlled. Rivetira is architected for that reality from the edge up.
Certified
SOC 2 Type II
Annual audit covering security, availability and confidentiality of the control plane.
Supported
ITAR / EAR aware
US-person access controls, on-prem and air-gapped deployment for controlled programs.
Mapped
AS9100 alignment
Quality records, NCR flow and traceability mapped to aerospace quality requirements.
In progress
ISO 27001
Information security management system certification underway. [PLACEHOLDER: target date]
Data stays where the airframe is
- Factory edge runtime holds all program geometry, imagery and metrology locally
- Air-gapped mode: model updates arrive by signed media, telemetry never leaves
- Per-tenant isolation and per-program cryptographic separation
- Encryption in transit and at rest; customer-managed keys available
Assurance-grade by default
- Immutable audit trail for every agent action, sensor reading and human override
- SSO/SAML, SCIM provisioning and role-based access down to station level
- Fail-safe stop for drills, fasteners, crawlers and cranes at < 40 ms
- Human-in-the-loop mandatory for airworthiness-critical dispositions
What changes on the floor
Plant directors, liaison engineers and airworthiness leads on what autonomy did to their numbers.
“We stopped arguing about whether the gap was 0.4 or 0.6 millimetres. The twin predicted it, the shim came off the machine right, and the join closed in one pass.”
−64% shim hours per join
“The rate ramp was going to cost us four more positions. Instead the line rebalanced itself every shift and we found the capacity inside the stations we already had.”
+38% delivered rate
“Every hole is now inspected, not one in four. My airworthiness record writes itself, and I can hand an auditor a complete trace in ninety seconds.”
100% inspection coverage
Which capability moves your number first?
A line assessment maps one station, quantifies the rework, shim and rate opportunity, and returns a modelled ROI in three weeks. No production disruption.