Manufacturing & Reliability

Southwest Research Institute supports the manufacturing industry with advanced automation technology, creating adaptable tools and robot systems while providing workforce training. We also help ensure that aging infrastructure and new products meet or exceed standards for safety, durability and performance.

For air travel, conducting bird strike analysis and testing is crucial for aviation safety to identify and mitigate risks associated with inflight collisions with birds. By analyzing structural responses to bird impact, aircraft manufacturers can develop designs to withstand these events in compliance with Federal Aviation Administration regulations. Using detailed dynamic finite element analysis, SwRI helps manufacturers develop impact-resistant components, an approach designed to protect human lives and enhance the overall efficiency and reliability of air travel.

Image

This finite element simulation analyzes the impact of a bird surrogate into a fuselage-mounted antenna system.

SwRI used Deep Neural Networks (DNNs) to predict the remaining useful lifetime of aircraft engines, significantly advancing predictive maintenance for the aviation industry. The system processes engine performance data, current operating conditions and maintenance records, allowing the system to learn and recognize subtle indicators of engine wear and other issues over time. Major airlines and aircraft manufacturers are adopting this technology to optimize maintenance schedules, reduce downtime and enhance safety. In 2024, improvements in DNN architectures and training algorithms increased prediction accuracy, making the technology more accessible and cost-effective for smaller operators.

To support industrial automation, SwRI used human-machine interactions to allow robots to blend and finish components in a metal foundry.

For 29 years, SwRI has operated the Texas Manufacturing Assistance Center, supporting small and medium manufacturers in South Central Texas with automation and process improvement solutions. Regional demand for manufacturing assistance continues to expand, to help defense contractors navigate cybersecurity compliance standards and growth in the automotive and semiconductor industries.