Value chain &
Business areas

Value chain

Alestis is an integrated aerostructures supplier for the different phases of the product life cycle, for OEMs and large Tier 1 companies.

Alestis is an integrated aerostructures supplier for the different phases of the product life cycle, for OEMs (Original Equipment Manufacturer53), and large Tier 1 companies. We offer capabilities and competencies, design, development, certification, manufacturing, assembly, delivery, final assembly line (FAL), and service support in a competitive and long-term manner. Our strategy is based on continuous improvement and investment in research, development and constant innovation, through which we develop optimization projects, improve designs and processes, and reduce costs.

In addition, Alestis can support customers worldwide in their offset management.


53. Aircraft integrators such as Airbus, Boeing, Dassault Aviation or Embraer.

Business areas

The core business of Alestis is the design, development, manufacturing and assembly of aerostructures.

Alestis is specialized in composite manufacturing, for which we have all the existing technologies on the market to offer the most competitive solution:

  • Automated Fiber Placement (AFP)
  • Automated Fiber Lay-up (FLU)
  • Automated Tape Lay-up (ATL)
  • Hand Lay-up
  • Resin Infusion

2022 was a year of relaunching face-to-face commercial activities, with active participation in trade fairs after the Covid19 crisis, where direct contact with customers was restored, reinforcing the company's strategic positioning and attracting commercial leads in the form of requests for quotation or interest above the pre-Covid annual average.

Direct commercial activities were coordinated with Aciturri Aeroestructures to offer one of the largest industrial capacities for manufacturing composite aerostructures on the world market.

Alestis participated in several trade shows this year: ADS Seattle, ADM Seville, Farnborough Air Show, NBAA-Orlando and the EXTENDA Direct Trade Mission of the Andalusian Government in Florida.

Likewise, 2022 was a transition year for the new projects that have joined the company in recent years:

Business Aviation

Dassault Falcon F10X.

Military Aviation - Defense

Calidus B250. The milestones for the design and manufacturing of the first qualification parts and the new tooling reception have been met, with the goal of starting the test prototype deliveries in the next few months.

Commercial Aviation

Airbus A220. During 2022 the first units were manufactured to start the final certification process, with assembly at the customer's facilities and thus obtaining approval for the series launch.

In Customer Support & Services (CS&S), activity in 2022 focused on consolidating MRO and services, mainly in the Defense sector, with a strong policy of integration and development of its own qualified resources, absorbing the subcontracted personnel of AEROSERV in the AIRBUS A330MRTT service in Getafe, together with an increase in its own personnel, which has doubled in 2022. This growth was necessary to take on the commercial commitments in the Military MRO area for 2023.

The trend of increasing production rates in most of the OEM programs in which Alestis participates, which started in 2021, continued:

AIRBUS

BF A350 XWB: 51 aircrafts
S19.1 A350 XWB: 52 aircrafts
HTP A320: 236 aircrafts
PAX DOORS A330: 26 aircrafts
HTP A330 Parts:  27 aircrafts
A380 TB: 6 aircrafts services bulletin

BOEING

Flaperon B777 COM: 26 aircrafts
Flaperon B777 Skin: 24 aircrafts

EMBRAER

Wing & Empennage Legacy 450/500 /Praetor: 42 aircrafts
Composites for Legacy 450/500/Praetor: 29 aircrafts

AIRBUS DEFENCE &SPACE

Fuselage C295: 11 units
Cowlings A400M: 7 units
Elevator A400M: 7 units

ACITURRI

WtFF A400M: 6 aircrafts
FR93 A350XWB: 28 aircrafts

Deliveries are made to the following locations:

-     Getafe, Illescas, Tres Cantos (Madrid, Spain).

-     Puerto Real (Cadiz, Spain)

-     Seville (Spain)

-     Saint Nazaire (France)

-     Toulouse (France)

As part of Alestis Aerospace's diversification strategy, significant progress has been made in the development of hydrogen tanks, progress related to product development plans in which the milestones established with mechanical tests carried out at INTA (National Institute of Aerospace Technology) and other accredited laboratories have been satisfactorily met, confirming their satisfactory evolution.

During 2022, we were able to establish various lines of collaboration with relevant companies within the hydrogen ecosystem, participating in consortiums such as the Puerta de Europa Hydrogen Cluster and exchanging confidentiality agreements with several companies for collaborative work.

A particularly important event was the formal approval of the ValorH2 project by the CDTI, a project in which Alestis is a fundamental participant in the hydrogen storage chapter and which defines some technological challenges to be overcome in the coming years.

In 2022, there has been an important evolution in the field of automation and robotics. In recent years, a robotics and automation team has been created, which has allowed the company to develop robotic cells and other automation projects internally, thus allowing a significant reduction in investment CAPEX. This team is responsible for the design, integration and installation of the robotic cell, as well as PLC/SCADA programming and robot programming. Between 2021 and 2022, Alestis has developed in-house deep learning machine vision software ("Deep Learning Quality Checker") for defect inspection and part recognition.

The trend of increasing production rates in most of the OEM programs in which Alestis participates, which started in 2021, continued.

The projects developed from this area during 2022 are:

New ultrasonic inspection cell installation.

Drilling and trimming cell.

The robot is equipped with a low-cost electric drilling head with automatic tool change.

Automatic polishing booth for skins.

Automation of the skins surface preparation prior to the painting process, including automatic sanding and cleaning with active control of the force applied by the grinder.

Kanban tray inspection station using artificial vision and Deep Learning.

Identification of possible fitting shortages in the tray and whether the fitting is located in the correct slot.

In 2022, the artificial vision inspection table, a project currently in the integration stage, was also launched. It is a Cartesian robot that is used to make a camera scan with the "Deep Learning Quality Checker" software, which was developed internally for the detailed part defect detection. It is designed to detect pores, scratches, paint defects, countersink quality, etc. A high-precision laser profilometer is used for measurement.

In addition, innovation projects for the production of composite materials in hand lay-up were developed during 2022.

Among the innovation projects for carbon fiber, the project for the use of reusable membranes in the curing process stands out. This new solution represents additional progress from an environmental point of view, as it reduces the consumption of auxiliary materials used in the production of detail parts.

"More than ever, we are aware of the need to be committed to the development of a sustainable industry, to be rigorous in the management of resources and ambitious in searching new opportunities, as guides that have marked our path and will guarantee the continuity of our project".

During 2022, innovation projects for the production of composite materials in hand lay-up have been developed.