3. SIPAL S.p.a.
The Sipal S.p.a. Engineering Department is specialized in designing complex Work Packages for the Aerospace
sector and in supplying onsite consultancy service.
More than thirty years of experience in the management of technologically complex project allows SIPAL to help
its clients with concrete ideas, rapid interventions and reliable solutions.
The Specialized Staff, deal with preliminary design, detailed design, process and product optimization, product
support and certification support throughout all steps to final assembly and certification.
All activities include project management, design and stress analysis.
4. Company General Data
Offices
HEADQUARTER
GALLARATE
Via Invorio, 24/A – 10146 Torino
CASSOLA
TORINO
PIACENZA
OPERATIONAL SITES
Via Monte Verena, 58/60 - 36022 Cassola (Vicenza)
Largo Camussi n. 8 - 21013 Gallarate (Varese)
Via Caorsana, 79 - 29100 Piacenza
Via Grotta delle Fate, 41 - 57128 Livorno
Via Affile, 102 - 00131 Roma
Via E. Gianturco, 23 - 80146 Napoli
C.so Giuseppe Garibaldi, 62 - 71121 Foggia
C.so Europa, 3 - 74023 Grottaglie (Taranto)
Viale Francia, 11 - 73100 Lecce
LIVORNO
FOGGIA
ROMA
NAPOLI
GROTTAGLIE
LECCE
5. Company General Data
SIPAL S.p.A. - General Data
Founded in Turin (ITALY) in 1978, SIPAL is the Engineering Company of the FININC S.p.A. Group since 1988 and
represents in the national scene a strong and reliable partner, in both civil and military field.
SIPAL is now active on the market in three main fields of :
Product and Manufacturing Engineering
Civil Engineering and Infrastructure
Integrated Logistic Support (ILS)
SIPAL’s Turnover
2013 € 25.000.000 (expected achievement)
2012 € 20.500.000 (+27%)
2011 € 16.150.000
2010 € 15.100.000
SIPAL’s Employees
More than 300 employees
90% Technical Degree (Master & Bachelor)
9. Core Business
Product Engineering
AEROSPACES SYSTEMS
Pre-project/preliminary studies on systems
Wiring and pipeline layout design
Electric, hydraulic, fluidic and flight control installation design
Onboard systems installation design
Electronic Design on Customer Specifications
Special systems and data network design
10. Core Business
Product Engineering
Main Activities
B787-8, B787-9 (Alenia-Boeing – Section 44, 46 and 49)
787-8 (Alenia) - Stress and Design activity (from concept layout to certification
dossier) for Main Structure and Systems Integration (Frame, Passengers Door
Surround, Cargo Door Surround, Cargo Beam Assy, Floor Beams, EEBay Door
Surround, Hydraulic, Wiring,);
787-8 (Alenia) - Stress and Design activity (from concept layout to certification
dossier) for Systems Integration (Hydraulic, Wiring,);
787-8 (Alenia) - Engineering support for Final Assembly Line (Everett, Charleston,
Grottaglie);
787-9 (Alenia) - Stress and Design activity for Main Structure and Systems
Integration
Primary structure design (composite and metals) using CATIA V5;
Parts sizing (static and fatigue analysis) using Boeing Tools, hand calculation
methods and FEM (Nastran, Patran, Hypermesh);
11. FUSELAGE SECTION 46 - Boeing 787
AERONAUTICAL STRUCTURES
Passenger Door Surround
Cargo Door Surround
12. CARGO FLOOR - Boeing 787 Program
AERONAUTICAL STRUCTURES
•
•
•
Design using CATIA V5
Primary structure design (composite and metals)
Parts sizing (static and fatigue analysis) using tradictional
methods and FEM
13. CARGO FLOOR - Boeing 787 Program
Frame
(composite material)
Machined element
(Titanium alloy)
AERONAUTICAL STRUCTURES
Floor Beam
(composite material)
Machined element
(Aluminum alloy)
Stiffners
(composite material)
Frame to skin-tie element
(composite material)
14. CARGO FLOOR - Boeing 787 Program
AERONAUTICAL STRUCTURES
•
•
•
•
Detailed analysis using FEM:
Joints
Stress of machined parts
Strain of composites elements
Machined element
(Aluminum alloy))
Floor Beam
Skin with stiffners
15. CARGO FLOOR - Boeing 787 Program
AERONAUTICAL STRUCTURES
Analysis of results (the picture shows the displaicement of the structure)
16. DOOR SURROUND - Boeing 787
•
AERONAUTICAL STRUCTURES
•
The detailed FEM model created by Sipal has been integrated into the complete FEM model
of the fusolage section created by Boeing.
The analyzed structural parts are made of titanium alloy (shown into red box).
17. DOOR SURROUND - Boeing 787
AERONAUTICAL STRUCTURES
Analysis of results (the picture shows the stress over the metallic parts)
18. Core Business
Product Engineering
Main Activities
BOMBARDIER C-SERIES (Salver-Magnaghi)
Design activity (from concept layout to certification dossier) for Main Structure
(Composite Inboard and Outboard Flap, Composite Main Landing Gear Door,
Composite Spoiler);
Primary structure design (composite and metals) using CATIA V5 and FiberSim;
Parts sizing (static and fatigue analysis) using hand calculation methods and FEM
(Nastran, Patran, Hypermesh);
Stress and F&DT Analysis.
19. AERONAUTICAL STRUCTURES
FLAPS - C-Series Program
•
•
•
•
Design using CATIA V5
Primary structure design (CFRP and Metals)
Study of Cinematics
Parts sizing (Static, Fatigue and Damage Tolerance analysis)
20. FLAPS - C-Series Program
AERONAUTICAL STRUCTURES
•
•
•
Design using CATIA V5
Primary structure design (CFRP and Metals)
Parts sizing (Static, Fatigue and Damage Tolerance analysis)
21. Core Business
Product Engineering
Main Activities
P-180 AVANTI – MPA3 (Piaggio Aero Industries)
Design Activities:
Wing, Center Fuselage and Bulkhead;
Wing - Flight Control System;
SYSTEM (Design and Installation: Fuel System, Avionic System, Wiring
Harness)
Primary structure design (composite and metals) using CATIA V5.
22. WING - Piaggio Aero Industries, MPA Program
AERONAUTICAL STRUCTURES
•
•
•
Design using CATIA V5
Primary structure design (CFRP and Metals)
Parts sizing (Static, Fatigue and Damage Tolerance analysis)
23. Core Business
Product Engineering
Main Activities
P-1XX (Piaggio Aero Industries)
Definition of Design Principles; Design of Front Fuselage; Design of Wing
Box; Design of Interiors; Design of Cockpit Mock-up; Design of Engine Pylon
and Power Plant Installation.
P-1XX (Piaggio Aero Industries) - Definition of Design Principles - Design of
Fuselage, Cockpit Mock-up, Engine Pylon and Power Plant Installation
24. COCKPIT - P1XX Program
AERONAUTICAL STRUCTURES
•
•
Design using CATIA V5
Primary structure design (metals)
25. WING - P1XX Program
AERONAUTICAL STRUCTURES
•
•
•
Design using CATIA V5
Primary structure design (metals)
Parts sizing (static and fatigue analysis) using tradictional methods and FEM
26. Core Business
Product Engineering
Main Activities
C-27J (Alenia)
Design of Flight Control System; System Installation
Integration and Testing of Avionic Sub-Systems
System modeling and simulation of electromagnetic fields
EF-2000 (Alenia)
Design of Wing Box; Design of Fuselage Electro Mechanical and Hydraulic
System; Design of Dass Pod
Integration and Testing of Avionic Sub-Systems
Analysis and preliminary design of the propulsion and overall systems
Analysis of stability and handling qualities
SKY-X (Alenia)
Design of all Airframe, Metallic Fuselage, Composite Nacelle, System
integration, System installation, Control Surface and Mechanism design, Flight
controls design, Power generation and distributions system design, Engine
Installation
27. Core Business
Product Engineering
AW169 (Agusta Westland)
Design of Composite Tail Plane
NH90
Stress analysis and report:
• Rear ramp
• End flap rear ramp
• Norway Observer Seat
• Weapon Integration Assy
Bird Strike analysis and report:
• Protection Tube
AW109
Stress analysis and report:
• New Pilot Collective Tube
Main Activities
28. Core Business
Product Engineering
A129BCH
Stress analysis and report:
• Co-Pilot Pedal Assembly
AW139
Design, Stress analysis and report:
• Rear cowling, IRSS Sistem
AW189
Stress analysis and report:
• Fixed Flight Controls
Main Activities
29. Core Business
Product Engineering
M-346 (Aermacchi)
Wing Box design and Weight optimization,
Aircraft Systems installation,
Qualification test support,
Aircraft Wiring and Harness Design,
Preliminary Pylon design,
Wing modification and integration
Composite /Metallic front fuselage design,
Harness installation,
Aircraft Ground Equipments design,
Tooling Design
Main Activities
30. WING BOX M346 – AERMACCHI
AERONAUTICAL STRUCTURES
Finite elements model for loads extractions and sizing using tradictional methods
•
•
•
•
•
•
WING BOX STRUCTURE (metal and composite materials):
spars
stringers
ribs
skin
fitting elements (pylon junction,hinges…)
31. WING BOX M346 – AERMACCHI
AERONAUTICAL STRUCTURES
•
•
Overall structure analysis (evaluation of the wing behaviour under
bending and torsional loads)
Detailed FEM analysis of critical items (loads concentration
factors near to fillets, complex jonts analysis, …)
32. Core Business
Engineering Support
MANUFACTURING ENGINEERING
Production and assembly cycles development
Definition of times and methods
Production plant sizing
Production cell workload and sizing analysis
Manufacturing Plan development
Production, assembly, support and test-set design and designation
Aerospace Ground Equipment design, management and qualification
Works Management and Safety Coordination
MANUFACTURING
Functional prototype and mock-up production
Production, assembly and support tools and electromechanical/hydraulic test sets
production
Aerospace Ground Equipment production
Electronic prototypes and test-sets production
Tool, machinery and plant upgrading and re-certification)
33. Core Business
Engineering Support
PCM-CYGNUS – MGSE 1-G FLOOR (Orbital)
MGSE Design, Analysis, Testing, Qualification;
DRD Technical Documentation , TAS-I PLANT TURIN
PCM-CYGNUS (Orbital)
Secondary Structure Static Test
Tool Design, Analysis and CE Technical Documentation
Main Activities
34. Core Business
Engineering Support
Main Activities
CLAMPING EQUIPMENT FOR FSW WELDING STATION
FSW Tool Design, Analysis , Manufacturing, Installation and Technical
Documentation.
A380 ENGINE NACELLE TOOL (Airbus)
Tool Design, Analysis and CE Technical Documentation
35. Engineering & Ground Test
Concurrent Engineering
Avionic Sub-Systems
General System & Propulsion
System Modeling
Flight Mechanics
36. Engineering & Ground Test
Concurrent Engineering
AVIONIC SUB-SYSTEMS (EFA-TORNADO-C27J)
Analysis and preliminary design of new generation avionics systems.
Multidisciplinary analysis of choice and integration of equipment / systems on
the aircraft.
Systems development, integration and testing of avionics subsystems.
Characterizations of aircraft antennas
Intra-system Testing between avionic equipments in order to detect
susceptibility
GENERAL SYSTEM & PROPULSION (EFA-TORNADO)
Analysis and preliminary design of the propulsion and overall systems starting
from the mission requirements
37. Engineering & Ground Test
Concurrent Engineering
SYSTEM MODELING (C27J)
System modeling and simulation.
Simulation of electromagnetic fields inside irradiated systems and subsystems.
FLIGHT MECHANICS (EFA)
Complete analysis of the performance.
Analysis of stability and handling qualities.
41. SIPAL Engineering Location and Capability
SIPAL ENGINEERING CAPABILITIES
Direct Employees
25 Structural Analysts
45 Designers
10 Methodists
10 Systems Engineers / Avionics / Propulsion
1 Composite Structures Expert
1 Systems Installation Expert
1 Equipment Expert
1 Tooling Expert
150.000 Hours / Year Developable
SIPAL TORINO - PIEMONTE
800 mq
Call conference room
Conference halls
Separable areas
100 stations set up with network/phone
Network and Storage Server
40 employees 8 STR / 22 DES / 10 AVIONICS
Engineering Location & Capability
42. SIPAL Engineering Location and Capability
SIPAL FOGGIA - PUGLIA
100 mq
Call conference room
Conference halls
Separable areas
6 stations set up with network/phone
Network and Storage Server
5 employees 1 STR / 4 DES
SIPAL NAPOLI - CAMPANIA
400 mq
Call conference room
Conference halls
Separable areas
30 stations set up with network/phone
Network and Storage Server
29 employees 11 STR/18 DES
Engineering Location & Capability
SIPAL GROTTAGLIE - PUGLIA
400 mq
Call conference room
Conference halls
Separable areas
24 stations set up with
network/phone
50 Network spots.
Network and Storage Server
16 employees 5 STR/11 DES
43. Certifications
UNI EN ISO 9001:2008
UNI EN 9100: 2009
Security
EAD Restricted Areas (NATO SECRET)
Partecipations
Complete Security Clearance (NOSC NATO SECRET)
COMSEC Areas (NATO SECRET)
44. Thanks for the attention!
Prepared by Ing. Alessandro Barretta
