Swinburne University’s AIR Hub has launched the META2.0 project, revolutionising UAV manufacturing by integrating automation, digital engineering, and advanced composite materials for high-rate aerospace production.
In an exclusive interview with Australian Manufacturing, Dr Adriano Di Pietro, CEO (Interim) of the Advanced Air Mobility CRC and Director of AIR Hub, emphasised that META2.0 represents a leap forward in UAV aerostructure production, particularly in thermoplastic composite manufacturing.
“The capabilities developed in this project at the Swinburne-CSIRO National Industry 4.0 Testlab represent a major step forward in UAV manufacturing, enabling Australia to address the growing needs of the air delivery and cargo sectors with cutting-edge high-rate production techniques.”
Advancing aerospace with thermoplastic composites
At its core, META2.0 introduces automated stamp forming of continuous carbon fibre reinforced Low-Melt Polyaryletherketone (LM PAEK) composites. This breakthrough reduces manufacturing times from hours to minutes, a first for Australia. Dr Di Pietro highlighted the significance of this material choice:
“LM PAEK composites offer lower processing temperatures, reducing energy consumption and simplifying production while providing excellent thermal stability and mechanical properties, including high impact resistance and durability.”
This process enables scalable high-rate production, maintaining the structural integrity and quality essential for UAV components. Beyond material innovations, META2.0 pushes the boundaries of digital twin technology and process simulations, optimising production accuracy and predicting performance outcomes.
Automation, digital engineering, and real-time analytics
META2.0 integrates Industry 4.0 technologies, creating a responsive manufacturing ecosystem. Dr Di Pietro explained how these elements work together:
“Automation plays a central role in reducing human error, accelerating production cycles, and ensuring consistent quality. Digital engineering leverages tools such as digital twins and finite element modelling to simulate and optimise manufacturing before physical production starts. Real-time data analytics continuously monitors key variables like temperature and pressure, enabling immediate adjustments to maintain optimal conditions.”
This closed-loop system enhances precision and efficiency, minimising waste while ensuring high-quality composite aerostructures.
Global competitiveness and economic impact
Australia’s aerospace industry is evolving rapidly, and META2.0 aims to strengthen local manufacturers’ ability to compete globally. The high-rate stamp forming capability developed through this project reduces labour and energy costs.
“This efficiency allows Australian manufacturers to offer competitive pricing in the cost-sensitive global aerospace market, without compromising on performance or quality,” Dr Di Pietro noted.
Additionally, scalability is a key advantage, allowing rapid production of complex parts. This makes Australia an attractive destination for global partnerships and investment in aerospace manufacturing.
Sustainability and resource efficiency
META2.0 aligns with sustainability goals by improving resource efficiency and reducing material waste. The use of pre-consolidated laminates, tailored to component geometry, minimises excess waste, while automation reduces defects and rework. Dr Di Pietro pointed out that the project is also exploring thermoplastic recycling:
“Materials like LM PAEK can be reshaped and recycled, making them inherently more sustainable.”
Future developments and industry impact
The next phase of META2.0 will focus on further optimising UAV aerostructure manufacturing, refining digital twin technology, and improving automated joining techniques. According to Dr Di Pietro:
“A major step involves using high-fidelity numerical simulations to model complex manufacturing processes, such as material behaviour during forming, before physical production begins.”
By leveraging Industry 4.0 innovations, the project is expected to drive further advancements in UAV production.
The content of this article is based on information supplied by Swinburne University and Dr Adriano Di Pietro. Please consult a licenced and/or registered professional in this area before making any decisions based on the content of this article.
