"The best dry ice blasting machine tested for industrial aircraft manufacturing" – Diehl Aviation in an expert interview

In the aviation industry, the highest levels of precision, quality and safety are essential. Every component must meet strict standards and must not be compromised by the manufacturing process. To meet these requirements, Diehl Aviation at its Laupheim site (Germany) relies on innovative cleaning technologies. Efficiency plays a particularly important role in tool cleaning – this is where dry ice blasting comes into play.

In this interview, Felix Mehre from Diehl Aviation discusses the challenges in production, the industry’s high standards and how the use of an ASCO dry ice blasting machine has optimised the cleaning process.

Could you please briefly introduce yourself and your company?
We are a leading supplier to the aviation industry and specialise in the development and production of high-quality components and modules for cabin interiors. At our site in Laupheim, we manufacture, amongst other things, side panels, ceiling panels, overhead luggage compartments, partition walls, crew rest areas and air conditioning components. These elements are essential for the interior of modern aircraft and contribute to safety, efficiency and comfort on board. In my role, I am responsible for the industrialisation of new products and also oversee the optimisation of existing series production to ensure the highest quality and efficiency.

What role does your company play in the aviation industry?
We are a so-called Tier 1 supplier, which means that we work directly with the major aircraft manufacturers and provide them with our bespoke solutions. Our range of services includes the development, production and supply of new parts and spare parts for the aviation industry. In addition, we also offer specialised solutions for the retrofit business with airlines to retrofit or modernise existing aircraft. This broad portfolio enables us to respond flexibly to our customers’ requirements and provide innovative solutions for cabin interiors.

What specific requirements or standards do you face in your industry?
The aviation industry is one of the most demanding sectors of all, as it is subject to the highest quality and safety standards. Every component we manufacture must undergo rigorous testing and withstand the most extreme stresses. Furthermore, as a production site in Germany, we are in direct competition with international manufacturers, which requires continuous optimisation of our manufacturing processes. Efficient, safe and cost-effective processes are therefore essential for us to meet our customers’ high demands and remain competitive.

What cleaning processes or technologies did you use before dry ice blasting?
Before introducing dry ice blasting, we had already been using other non-abrasive cleaning processes. These were designed to treat sensitive surfaces gently, but often required special environments such as enclosed booths or separate cleaning areas, which made the process less flexible.

What challenges do you face in cleaning or maintenance?
Our biggest challenges in cleaning and maintenance stem from several factors: many of the surfaces that need cleaning are extremely hot, which complicates the process. Furthermore, we often have to deal with heavy tools that are not easy to handle. On top of that, many areas are difficult to access and thorough cleaning without dismantling was often hard to achieve.

What made you decide on the ASCOJET 1701?
Were there any specific criteria that were particularly important to you? For us, the straightforward handling of the machine in our industrial environment played a decisive role. It was particularly important to us that the machine is ready for use quickly whilst offering high performance. The machine’s unrestricted endurance and available power reserve convinced us, as we needed a solution that would function reliably in the long term.

For which specific applications do you use the machine?
We use the dry ice blasting machine primarily for cleaning tools, particularly for our 500-tonne press. Here, effective yet gentle cleaning is essential to extend the service life of the tools and ensure an efficient production process.

How often and for how long do you use the machine in practice?
The machine is used on an as-needed basis and depends on the degree of soiling on the tools. As soon as cleaning is required, we deploy the machine specifically to ensure optimal cleaning performance without causing unnecessary downtime.

What immediate benefits have you noticed since introducing the dry ice blasting machine?
Since introducing the machine, we have seen a significant improvement in the quality of our cleaning process. A particular advantage is that we can now carry out interim cleaning without having to go to the trouble of dismantling or disassembling the tool. This saves us valuable time and enables a more efficient production process without compromising on cleanliness or quality.

Have you received any feedback from your staff or customers regarding the use of the machine?
Our colleagues in production are very satisfied with the machine’s cleaning performance and appreciate its flexibility. The cleaning is effective and noticeably makes day-to-day work easier. The only drawback is the noise level of the process, which cannot be avoided – here we rely on suitable personal protective equipment (PPE) to minimise the noise level for staff.

Diehl Aviation website