H2 Clipper (H2C) has been granted US Patent No. 12,234,035 for its system that uses autonomous and semi-autonomous robotic swarms in aircraft and aerospace manufacturing. This is the company’s fifteenth awarded patent and continues its earlier robotics patent (No. 11,851,214) issued in December 2023.

The new patent covers the use of Swarm Robotics to reduce manufacturing time and cost while increasing precision and enabling 24/7 automated production. H2C says the system replaces traditional assembly lines with a coordinated robotic network that assembles structures, installs components, performs inspections and carries out high-precision tasks.

H2C founder and CEO Rinaldo Brutoco says: “The issuance of this patent marks a pivotal moment in the evolution of aerospace and aviation manufacturing. By replacing traditional assembly lines with robotic swarms, this breakthrough enables aircraft and large aerospace assets to be built faster, at a significantly lower cost and with far greater precision.” He adds that the system could cut total manufacturing costs by 40 per cent and reduce timelines by up to 60 per cent.

The technology uses machine learning and generative AI to guide the swarm, helping it self-correct and improve accuracy. Built-in sensors and AI oversight allow safe, collision-free operation and remove the need for human workers at dangerous heights.

Heavy-lift robots enable horizontal or vertical construction in place without moving aircraft through stages, which helps reduce space and infrastructure needs. H2C developed the system for its Pipeline-in-the-Sky airships but saw its wider use across the aerospace industry.

H2C plans to form a team of aerospace, AI, robotics and manufacturing experts to guide the next stage of development and support potential licensing. A renewed agreement with Dassault Systèmes in 2024 extends their partnership for software development over the next three years.