PROJECT AILE

​AILE is a major R&D program led by Bombardier, in collaboration with several key partners from the Canadian aerospace sector. The initiative builds on the advances introduced with the Global 7500’s electric flight controls, with a clear objective: fully leverage these technologies to integrate new aerodynamic and structural functionalities into a next-generation wing.

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Program Objective

Develop an intelligent, lightweight wing equipped with multifunctional flight control surfaces that meet the performance requirements of future business aircraft.

The project addressed several critical industry challenges:

• structural weight reduction while improving aerodynamic efficiency,

• advanced synchronization between flaps and spoilers,

• technology maturation from TRL 3 to TRL 6,

• full system validation on a dedicated test bench and flight simulator.

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Key Outcomes

The AILE program led to the design and fabrication of a full test bench accurately replicating the left flap (real geometry and representative mechanical loads), combined with a numerical model of the right wing.
A dedicated flight simulator was also developed to precisely characterize system performance in a representative environment.

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FusiA Impression 3D Métal Inc. Contribution

FusiA played a key role in structural light-weighting and optimization through metal additive manufacturing.

Our contribution focused on:

• the design of a topology-optimized flap hinge,

• the fabrication of prototypes using metal additive manufacturing (ALM),

• the delivery of parts tested and validated by Bombardier on the test bench.

Direct benefits of additive manufacturing:

• significant reduction in structural mass,

• integration of complex geometries impossible to achieve with conventional machining,

• improved flap performance and opportunities for further wing-level weight reduction.

This contribution demonstrates FusiA’s capability to support critical aerospace R&D programs.

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Towards More Sustainable Aviation

AILE aligns with the sector’s environmental objectives by embedding impact reduction directly into the design phase.

Identified benefits include:

• lower structural mass,

• reduced fuel burn,

• decreased GHG emissions,

• more efficient use of materials.

Life-cycle assessments indicate a potential CO₂ reduction exceeding 170,000 tonnes for a fleet equipped with this technology.

For FusiA, this project reaffirms our capability to deliver critical additive-manufactured components that meet the standards of demanding R&D programs while supporting the industry’s sustainability ambitions.