Automated Stretch Wrapping for Aerospace & Defense
Secure delicate composite panels, massive wing spars, fuselage sections, stringers, thin-wall tubing, and irregularly shaped defense components. Deploy CapEx-grade orbital stretch wrapping machines engineered with extreme dimensional precision and soft-start vibration reduction. Featuring native SCADA, ERP, and MES connectivity (via OPC UA, MQTT, and EtherNet/IP) for total traceability, real-time predictive maintenance diagnostics, CIP Safety perimeter compliance, and ESD Anti-Static film integration for sensitive avionics.
Explore the Core Technology: View our complete lineup of Horizontal & Orbital Stretch Wrapping Machines.
The Precision Bottleneck: Protecting Delicate Composites
Whether you are packaging solid extrusions, hollow tubing, or fragile coiled parts, aerospace carbon fiber and composite panels are highly sensitive to localized stress. Traditional strapping easily crushes honeycomb cores, and aggressive machine startups induce dangerous vibration that damages delicate layups.
The Solution: Distributed, calibrated tension and smooth physics. Engineered for clean-room compatibility, the Dynawrap Pro 1900 utilizes a pre-stretch carriage with highly programmable wrap patterns via a touch-screen HMI control. Paired with fully automatic clamping and film cutting, the machine executes a soft-start/soft-stop ring rotation. With precision-controlled ring speeds up to 50 RPM, it secures irregularly shaped components perfectly without ever inducing stress fractures or localized crushing on thin-wall parts.
The Scale Bottleneck: Six-Sided Encapsulation
Defense contractors routinely package oversized components like missile tubes, wide radar panels, and massive wing spars (often exceeding 20 feet long). These multi-million-dollar components completely dwarf standard industrial wrapping equipment and require maximum protection for finished assemblies.
The Solution: Operating as a true six-sided orbital wrapper, the massive Dynawrap Pro 2200 (with welding unit) easily handles payloads up to 5,000 lbs. Offering ring diameters from 24 to 87 inches (and beyond on custom orders), it wraps all six sides of long products. The automated welding unit drapes and seals a protective inner layer of PE bagging or foam directly over the massive assembly before applying the stretch film. This dual-layer encapsulation guarantees pristine cosmetic surfaces and absolute moisture protection.
The Data Bottleneck: SCADA & ERP Traceability
In aerospace manufacturing, black-box machinery is unacceptable. Facilities require total data logging, verifiable cycle counts, and real-time operational status pushed directly to central facility command centers to maintain ISO and military compliance.
The Solution: CapEx-grade networking. Our Pro Series horizontal wrappers are designed from the ground up for total SCADA, ERP, and MES connectivity. Utilizing flexible enterprise PLC architectures (Beijer, Siemens, Allen-Bradley, and Beckhoff), the machines connect seamlessly to plant networks via EtherNet/IP, PROFINET, and native OPC UA servers. This enables direct string-based data exchange with your WMS for automated production orders, while MQTT telemetry pushes real-time predictive maintenance diagnostics (VFD faults, cycle counts, and motor loads) directly to your cloud, delivering absolute data transparency and traceability for every aerospace component wrapped.
Enterprise Automation: Dynawrap LUMI™ 3D Algorithmic Vision
Eliminate human error entirely on critical defense contracts. Available as an option across the Pro Series, the LUMI™ System utilizes an Intel® depth-sensing 3D camera and a dedicated embedded controller to adapt to varying part sizes instantly.
Volumetric Scanning
As highly sensitive, irregularly shaped aerospace parts enter the zone, the system executes real-time 3D scanning to determine the exact geometry.
Automated PLC Handshake
Our proprietary algorithm automatically calculates and pushes the optimal wrapping parameters directly to the machine's PLC.
Zero-Touch Operation
Operators simply select 'Optimum' or 'Heavy' protection modes on the HMI, and the machine handles the rest - ensuring precision tension on delicate composites.
Military-Grade Safety: Robotic Cell Integration
Engineered for strict EHS compliance and absolute autonomy. Our wrappers serve as secure, integrated nodes for highly automated defense environments, supporting direct handshakes with FANUC, ABB, and KUKA robots.
Native SCADA Protocols
Seamless communication via EtherNet/IP, PROFINET, Modbus TCP, OPC UA, and MQTT for centralized ERP/WMS data exchange and telemetry logging.
Automated Handshakes
Standardized execution I/O (Ready, Start, Busy, Complete, Fault) allowing upstream robots to safely load and trigger wrapping cycles.
Predictive Maintenance
Stream real-time VFD faults, motor speeds, heater temperatures, and cycle counts directly to command centers to eliminate unplanned downtime.
EHS Perimeter Safety
Advanced CIP Safety and PROFIsafe network integration, paired with hardwired optical light curtains for zero-touch, fail-safe operational security.
Defense Consumables Ecosystem
Aerospace manufacturing involves highly sensitive avionics, actuators, and electronic control systems. Standard plastic stretch films naturally generate significant static electricity as they unroll, which can instantly fry microprocessors and sensitive defense electronics during the packaging process.
To protect critical electromechanical assemblies, we strictly mandate our Anti-Static (ESD) Stretch Film. Engineered with highly effective anti-static additives, this film completely eliminates electrostatic discharge (ESD) during the wrapping cycle.
• VCI (Anti-Rust) Film: For raw metal machined assemblies.
• Hybrid PE Foam Integration: Our 'W' series wrappers can apply foam or nonwoven fabric beneath the stretch film to protect precision cosmetic surfaces.
• Cast Clear Film: For standard inert composite materials requiring high clarity.
Technical FAQ: Aerospace & Defense Orbital Wrapping
How does the orbital wrapper prevent localized crushing or micro-fractures when securing thin-wall aerospace composites and honeycomb panels?
The Dynawrap Pro series utilizes a closed-loop pre-stretch carriage combined with soft-start/soft-stop ring rotation up to 50 RPM to eliminate vibration and sudden load shifts. The programmable HMI allows operators to set exact distributed film tension, ensuring delicate structures like composite panels and wing spars are secured without concentrated stress points.
Can the wrapping system provide true six-sided encapsulation for multi-ton, oversized defense components like missile tubes?
Yes, the Dynawrap Pro 2200 accommodates payloads up to 5,000 lbs and features ring diameters up to 87 inches to handle massive aerospace geometries. It integrates an automated welding unit that drapes and seals a protective inner PE or foam layer prior to stretch wrapping, creating a hermetic six-sided seal against moisture and cosmetic damage.
What mechanisms are in place to prevent electrostatic discharge (ESD) from damaging sensitive avionics during the stretch wrapping cycle?
Standard plastic stretch films generate substantial static electricity as they unroll, which can easily destroy microprocessors. To prevent this, the wrapping cells are calibrated to seamlessly deploy specially engineered Anti-Static (ESD) Stretch Film, which features anti-static additives to completely neutralize electrostatic discharge during packaging.
How does the automated cell integrate with existing SCADA networks and CIP Safety perimeters in highly regulated defense manufacturing environments?
The equipment features native OPC UA servers, EtherNet/IP, and PROFINET capabilities via Beckhoff, Siemens, or Allen-Bradley PLCs for seamless ERP/WMS handshakes and MQTT telemetry data logging. For EHS compliance, the wrapper acts as an autonomous node utilizing CIP Safety network protocols and hardwired optical light curtains to safely interface with robotic loading systems like FANUC or ABB.
Automate Precision Packaging
From CIP Safety compliant robotic handshakes to massive wide-ring capacities, our automated cells are engineered for the extreme requirements of defense and aerospace contractors. Tell us if you are wrapping delicate composite structures, oversized missile tubes, or sensitive avionics requiring ESD Anti-Static film integration. Request a custom facility review today.