Rolls-Royce’s FutureWorks: Pioneering digital innovation in aerospace manufacturing

Rolls-Royce’s FutureWorks facility in Bristol is at the forefront of revolutionising aerospace manufacturing and skills for the Future Combat Air System (FCAS) programme and wider industry.

With a key focus on advanced technologies and capabilities across propulsion and integrated power systems, the facility is driving a shift from traditional production methods to a cutting-edge digital environment that aims to streamline processes, reduce costs and develop skills needed for the future of engineering.

FutureWorks is advancing toward a vision of a ‘paperless factory’, aiming to embedded digital solutions throughout its production lines.

 

One of the most exciting advancements at FutureWorks is the integration of Additive Layer Manufacturing (ALM), which allows the team to produce custom tooling rapidly and onsite, cutting down on waste, costs and delays that occur when there is a need to source tools for specific elements of a project.

The team are also experimenting with (ALM) to recycle on-site waste materials. Although this work is still under development, such efforts reflect Rolls-Royce’s commitment to sustainable practices and the ability to ‘trial and error’ novel ideas.

As FutureWorks continues to advance towards a vision of a ‘paperless factory’, digital solutions are being embedded throughout production lines. For instance, SMART tools and control systems are being trialled to replace traditional paper-based systems, helping to track equipment and processes with real-time accuracy for better efficiency.

The facility provides a dynamic space for teams to explore innovative solutions such as Augmented Reality (AR) and Virtual Reality (VR). By leveraging these digital tools, engineers and designers can collaborate more effectively, capture critical insights earlier in the design process and improve communication across the supply chain, reducing the risks of errors and delay in manufacturing.

Rolls-Royce Operation Manager for Future Programmes and FutureWorks Ryan Allen said:

FutureWorks has provided a designated space to find new and innovative ways of working, which will make the FCAS programme more efficient in terms of time and cost in both development and production phase.”


 

As the facility continues to evolve, the aspiration is for FutureWorks to be utilised for other digital technologies such as Digital Twins, Manufacturing Execution Systems (MES) and OpsCentre, which help manage, instruct and track production processes. These innovations are positioning Rolls-Royce as a Digital First company and helping to prepare the industry for a digital future.

Ryan further emphasised the broader impact of FutureWorks: “We’ve seen a whole host of benefits to the programme, especially through the increased use of exciting technologies and approaches that are helping the team to embrace and embed change. With the technology already in the hands of our engineers, we will continue to encourage and support them to innovate and help power the capabilities of tomorrow.”

Rolls-Royce’s FutureWorks is not only transforming current production processes but also fostering a culture of continuous innovation. By integrating new technologies, FutureWorks is helping to shape the future of aerospace manufacturing, ensuring Rolls-Royce remains at the forefront of industry advancements.

About Rolls-Royce Holdings plc
  1. Rolls-Royce develops and delivers complex power and propulsion solutions for safety-critical applications in the air, at sea and on land. Our products and service packages enable our customers to connect people, societies, cultures and economies together; they meet the growing need for power generation across multiple industries; and enable governments to equip their armed forces with the power to protect.
  2. Rolls-Royce has a presence in 48 countries and customers in more than 150, comprising over 250 commercial large aero engine customers, 160 armed forces and navies and approximately 40,000 active Power Systems customers. We are committed to becoming a net zero company by 2050 and we support our customers to do the same.
  3. Annual underlying revenue was £15.4bn in 2023, underlying operating profit was £1.6bn and free cash flow £1.3bn.
  4. Rolls-Royce Holdings plc is publicly traded company (LSE: RR., ADR: RYCEY, LEI: 213800EC7997ZBLZJH69)
  5. Rolls-Royce Deutschland is the only aircraft engine manufacturer in Germany certified to develop, manufacture and maintain modern civil and military turbine engines. The company employs approximately 3,500 people at its facilities in Cottbus, Dahlewitz, Munich and Oberursel. Rolls-Royce Deutschland’s annual turnover in 2023 was more than 1.8billion Euro. So far, Rolls-Royce Deutschland has delivered more than 8,500 engines ‘made in Germany.’

www.rolls-royce.com

Register for news and stories

Our Alert service delivers the latest press releases, stories and regulatory news directly to your mailbox.