Introduction
In today’s fast-evolving manufacturing landscape, adopting advanced technologies like artificial intelligence and robotics is no longer optional, it’s essential. For TRYGONS S.A., a leading composite parts manufacturer and developer of high-performance maritime platforms, including dual-use unmanned surface vessels, integrating AI into their operations was key to addressing the need to improve placement accuracy, process repeatability, and production efficiency during a critical manual sandwich assembly stage involving the identification and precise positioning of foam core components between composite fabric layers..
Thanks to their collaboration with AI-MATTERS, TRYGONS S.A. was able to further refine, validate, and demonstrate its AI-enabled visual part recognition and projection-based operator guidance solution in a full-scale pilot under real production conditions, while systematically evaluating measurable performance indicators related to process time, material waste, cost efficiency, and overall process reliability. This is their story.
The Challenge
Every organization embarking on an AI transformation faces unique hurdles. For TRYGONS S.A., the main challenge was improving accuracy, repeatability, and efficiency in a critical manual sandwich assembly stage, where foam core components must be correctly identified and precisely positioned between composite fabric layers. Additionally, they needed support in developing an intuitive and easy-to-use human–machine interface that would allow smooth integration into the production environment, facilitate acceptance and everyday use by operators, and at the same time strengthen internal know-how for the future deployment of similar AI-supported systems.
“We saw a clear opportunity to address a demanding and error-sensitive stage of our production process with a more advanced and practical AI-supported solution” explains Evagoras Zervas, European Project Coordinator & Mechanical Engineer at TRYGONS S.A.
The Solution
AI-MATTERS provided TRYGONS S.A. with the resources and expertise they needed to overcome these challenges. Through specialized technical guidance, appropriate testbed equipment, and a production-relevant validation environment, the organization was able to further refine, pilot, and evaluate an AI-based visual part recognition and projection-guided operator support solution for sandwich assembly under real manufacturing conditions..
“AI-MATTERS supported us by providing a structured framework in which we could further develop and validate our solution in a practical and low-risk way”, says Evagoras Zervas
The Results
The collaboration between AI-MATTERS and TRYGONS S.A. delivered tangible outcomes. Some of the key results include:
- 30–35% reduction in process time in the sandwich fabrication stage.
- Improved process consistency and placement accuracy, contributing to lower material waste and more reliable execution of the sandwich assembly process.
- Approximately 15–20% reduction in related production costs, with longer-term potential for an additional 10–15% reduction in overall product cycle time when combined with further robotic-assisted handling.
“These results are particularly important for us because they combine efficiency gains with improved process consistency, product quality, and operator support.” adds Evagoras Zervas.
Looking Ahead
Working with AI-MATTERS has been a pivotal step for TRYGONS S.A. in their AI adoption journey. Moving forward, they plan to [further mature the solution toward full industrial readiness and fully incorporate it into its production processes. At the same time, TRYGONS intends to build on this experience by expanding similar AI-supported solutions across additional products and manufacturing processes, particularly in areas where accurate material handling, operator guidance, and process consistency are critical. More broadly, the company will continue investing in AI and robotics as part of its wider digitization strategy, with a strong emphasis on solutions that combine measurable operational value with practical support for operators on the shop floor.
“Working with AI-MATTERS strengthened our view that AI can deliver very practical value in manufacturing when it is closely aligned with real production needs,” concludes Evagoras Zervas, European Project Coordinator and Mechanical Engineer at TRYGONS S.A.
Conclusion
TRYGONS S.A.’s story demonstrates the transformative potential of AI in European manufacturing. By addressing challenges head-on and leveraging the resources of AI-MATTERS, they’ve paved the way for a future of smarter, more efficient operations.
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