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Expertise 31.07.2025
Tooling: A wide range of expertise serving the aerospace industry

In aeronautics, nothing can be done without tools. This equipment is essential for the smooth running of maintenance, assembly, and transport operations. It enables operators to perform precise tasks such as assembling a part, moving an engine, or holding a structure in place during an assembly operation.

At SEGULA Technologies, a wide range of expertise revolves around tooling, involving numerous employees at various sites. Among these talented individuals, in Marignane, in the south of France, a dedicated team led by Clément Le Flahec, Technical and Operations Manager for the business, designs tailor-made solutions to meet the sector’s specific requirements.

 

 

A tailor-made solution for every project

Each project begins with the receipt of specifications issued by the customer. An initial analysis is then carried out to assess the team’s ability to respond effectively to the request. If the green light is given, the project managers and designers take over to design a preliminary project. This phase includes costing, exploring the various technical disciplines involved, and developing a specific industrial plan.

Once the offer has been formalized and submitted, the project team springs into action to structure the rollout (drawing up a schedule, validating critical milestones, managing safety constraints related to end use, design, and finite element analysis). Manufacturing is then launched, followed by delivery and, if necessary, on-site installation. “On a day-to-day basis, the organization is based on a central duo consisting of the project manager and the designer. Both are responsible for technical consistency and act as the main point of contact for the customer. At the same time, a project team oversees cross-functional issues such as schedule compliance, budget management, and general reporting. This small team structure allows for smooth communication and better adaptation to the needs of each project.” Clément Le Flahec

 

Supporting major players in the aerospace industry

Design, certification, and shipping of Jackpads for Canada

SEGULA is collaborating with Airbus Canada on the A220 program to design a specific tool: the Jackpad. Essential for aircraft assembly, this component acts as an interface between the fuselage and the transport and handling cradles. For this project, SEGULA is responsible for the design, certification, and shipment of the jackpads. Only manufacturing is outsourced. The project is characterized by its regulatory complexity, as the jackpads must withstand heavy loads and comply with standards in four different countries. The team must integrate very strict technical requirements from the design phase, validated by calculation. Beyond the technical aspect, this contract illustrates SEGULA’s ability to establish itself as a trusted supplier internationally.

 

 

Design and manufacture of a transport trolley for aircraft engines

This equipment, ordered by Safran, is intended for heavy maintenance operations requiring the complete dismantling of engines. One of the major challenges is the versatility of the trolley, which must be able to adapt to several engine configurations (CFM56 and LEAP). This involves high technical requirements, particularly in terms of stability and geometric precision, as the engines, which can weigh between 4 and 7 tons, must be handled without deformation to ensure perfect alignment of the mechanical components during reassembly. The project is being managed from start to finish by SEGULA: design, structural calculations, PLC programming, manufacturing, certification, and on-site assembly by a dedicated team. Ergonomics is at the heart of the development process to ensure efficiency, comfort, and safety for operators.

 

 

“Before adapting to the machine, you have to adapt to the people who will be using it. To ensure that products are relevant to users, project managers and designers visit the field and talk to operators to better understand their specific constraints and needs.”

 

 

Clément Le Flahec, Technical and Operations Manager for all tools in Marignane

 

“Our strength lies in the diversity of our expertise. We offer tailor-made solutions, because every project is unique and requires constant adaptation. We are able to work in many different fields, from mechanical welding to machining, automation and composite molding. Each member of the team contributes their own area of expertise.”

 

 

 

Jean-Michel Caroul, Design Engineer

 

After completing his work-study program at SEGULA, Jean-Michel Caroul decided to continue his career with the Group. Now a design engineer, he works on a wide variety of projects, ranging from engine transport trolleys to drilling tools, turning systems, and test benches. “My job is to create custom parts that cannot be produced using standard methods. For example, if a panel needs to be moved, I have to design a custom trolley that will perform this specific function. Once the specifications have been established, I model the solution in 3D and check its feasibility. What I particularly enjoy is the diversity of the projects I work on. We can design anything from small boxes to more complex structures, such as civil engineering projects.”

 

 

 

 

Jeremy Stigliano, Project Manager, Tooling Design

 

With a technical degree in electronics, Jeremy Stigliano began his career in technical documentation before moving on to design offices. He now works as a project manager in tooling design at SEGULA. “My role is to respond to a need expressed by our customers through a set of specifications and to manage the entire development process from start to finish. What I particularly appreciate is being able to work on a variety of topics. We touch on everything: mechanics, manufacturing, packaging… It’s very comprehensive. I have the freedom to make suggestions and be proactive. If I identify a relevant solution or partnership, such as the one developed with Nodusfactory, I am given the resources to implement it.”

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