Turkish Aerospace Industries (TAI) shared new details in the 143rd issue of its corporate magazine GÖKVATAN regarding the Automated Positioning and Alignment Jig (APAJ) system, which has been commissioned on the assembly line of the National Combat Aircraft KAAN. The integration of this advanced system highlights the level of technological maturity achieved by Türkiye in defense aviation manufacturing. APAJ stands out not merely as a production tool, but as a cornerstone of the digital transformation of aircraft assembly processes.

Fifth-generation fighter aircraft impose extremely demanding requirements, including low radar cross-section, high geometric accuracy, hybrid material integration, and strict aerodynamic tolerances. These challenges push conventional fixed jig systems to their limits. In response, the APAJ system enables automatic positioning and alignment of integrated aircraft components through multi-axis servo-controlled actuators, laser-based tracking sensors, and real-time closed-loop control algorithms. By continuously comparing physical measurements with CAD models, the system performs automatic corrections with micron-level accuracy.

The system achieves repeatable positioning accuracy below ±0.1 millimeters, with overall alignment stability quantified using the Root Mean Square (RMS) positioning error parameter. This capability ensures structural integrity and surface continuity while maintaining the strict tolerances required for radar stealth characteristics. During the development phase, APAJ’s reconfigurable structure allows rapid adaptation to design revisions without the need for new fixture manufacturing, significantly shortening validation and engineering test cycles.

In the serial production phase, APAJ delivers repeatable quality and high operational efficiency to the assembly line. All positioning and alignment data are digitally recorded, enabling fully traceable quality control processes and effective root-cause analysis. Integrated with Product Lifecycle Management (PLM), Manufacturing Execution Systems (MES), and quality databases, the system brings the digital twin concept directly to the shop floor. As a result, APAJ emerges as a strategic technology that enhances precision, flexibility, and productivity in KAAN’s fifth-generation aircraft assembly operations.