FlexSort: transforming small component handling for Aerospace automation
Business challenge
Product Innovation
Process Innovation
Sector
Aerospace
Technology or capability
Materials Engineering
Automation & Robotics
As part of the CONVERGENCE programme driving innovation in aerospace manufacturing, MTC developed FlexSort—a fully integrated demonstrator system designed to automate the sorting and presentation of small batch components. This solution addresses a critical challenge in achieving consistent part presentation for downstream automation processes.
The Challenge
Manufacturers often rely on bespoke vibratory or linear feeders for part presentation, which can be costly and inflexible—particularly in low-volume, high-mix environments. Bulk packaging of tiny components adds further complexity, requiring significant manual effort to repack into trays or pallets.
MTC's Solution
MTC engineered a flexible component handling and palletising system that combines advanced robotics and automation technologies:
- Multi-tool gripper capable of picking and placing a range of components without tool changes
- Custom-designed pallets for easy integration and reconfiguration
- Dual flexible feeders to accommodate varying component types and sizes
- Integration of vision systems, feeders, and bespoke end-effectors for high reliability and adaptability
This solution is a great application of automated technologies demonstrating the ability to integrate vision systems, feeders and bespoke robot end effectors to selectively choose parts for a high reliability application.
Agata Suwala, Technology Manager, MTC
The Outcome
The demonstrator cell showcases a turnkey solution for an industry-wide challenge, achieving Technology Readiness Level (TRL) 4–6. Designed with safety in mind, it minimises manual intervention—limited to refilling hoppers and swapping pallets—while proving the viability of automation in kitting and palletising operations.
Benefits to the customer
When deployed in a manufacturing environment, FlexSort is expected to:
- Increase throughput for kitting operations
- Improve component traceability for quality assurance
- Enhance agility for low-volume, high-accuracy processes
- Free skilled operators to focus on value-added tasks
The impact
- 15% reduction in non-value-add time
- 100% traceable parts for improved quality control
- Enables downstream automation for greater efficiency