Starting with the early site-selection phase and continuing through final construction, Boeing turned to BRPH for design and engineering services for its new Composite Wing Center (CWC) in Everett, Washington. Encompassing more than 27 acres under one roof – the equivalent to 25 football fields – the CWC contains three of the world’s largest autoclaves, each big enough to fit two 737 fuselages inside. The cutting-edge facility produces the 777X composite aircraft wings, the longest wings Boeing has ever built.
The building’s 1.3 million-square-foot footprint is divided into two main areas: a 570,000-square-foot controlled contaminations area (CCA) with tightly controlled temperature and humidification to support the composite manufacturing process; and a 525,000-square-foot post-cure area of fully air-conditioned space. The post-cure area houses three autoclaves, paint booths with cure ovens, NDI testing, manufacturing trim, and storage. Each main area is supported by an automated guided vehicle for transporting the composite assemblies between the autoclaves and individual manufacturing work cells. Remaining ground floor common areas provide support to the manufacturing floor process.
The CCA and post-cure areas have a truss clear span to support under-hung bridge cranes that allow for full transit of pendant mounted cranes across the clear span area. Working closely with Boeing leadership, BRPH provided site selection, design and construction services to bring the project to life. Opened for full production in July 2020, the $1 billion facility supports production of the 777X variants, Boeing’s newest commercial aircraft.