Typical Projects: Smarter Manufacturing with Simulation

In aerospace manufacturing, specs are tight and timelines tighter. While process simulation can reduce risk by predicting defects and shortening cycle times, it’s often complex and resource-intensive to implement. Convergent US focuses on simplifying process simulation to deliver smarter, faster, and more reliable outcomes:

  • Resolved thermal compliance and optimized curing for heat blanket manufacturing

  • Predicted and minimized distortion in thin-ply composite aerospace structures (case study pending)

Explore the case studies below to see how our simulation-first approach delivers measurable results across aerospace programs.

Slide titled 'Heat Blanket Process Design & Optimization' with background text explaining heat blankets used as heat sources in manufacturing, and section headers 'Background,' 'Convergent US Approach,' and 'Typical Project.'
Diagram of a thermal process cycle with labeled control zones, a flowchart illustrating a heat blanket manufacturing process, and a schematic of the composite skin bond process on complex substructure. The image includes text detailing materials, pro
Slide titled 'Step 1: Create OSPREY Shape Template' showing a diagram of a rectangular shape with angled sections, accompanied by a list of components and guidelines for modeling thicknesses, and a table with materials and their maximum thickness and
Slide titled 'Step 2: Design & Perform Experimental Thermal Test' with text and a diagram. The diagram includes a RAVEN plot of duty cycle for all zones, a bar chart of different thermal components, and a legend for process cycle and duty cycle perce
Slide titled 'Step 3: Create Candidate OSPREY Heat Blanket' with two diagrams. The upper diagram shows a part structure with common thickness regions, and the lower diagram presents a proposed heat blanket zone layout. Text describes heat blanket mod