NEUF architect(e)s Delivers State-Of-The-Art Jet Manufacturing Facility for Bombardier at Toronto Pearson International Airport

ADF05/30/2024≫ Architect

State-Of-The-Art Jet Manufacturing Facility for Bombardier

New campus replaces the historic Downsview Facility and elevates Bombardier as a global leader in aerospace manufacturing

Bombardier Inc. (TSX: BBD.B) celebrates the grand opening of its leading-edge Global jet aircraft manufacturing campus at Toronto Pearson International Airport. Designed by NEUF architect(e)s, the 750,000 sq ft facility sets a new standard for enabling precision, efficiency, and sustainability in the aerospace industry, achieving an integrated workplace environment similar in complexity to a healthcare complex.

A specially designed 6-metre-high blast wall [model #G20NB-6] was constructed to protect the airport's operational areas from the powerful jet engine blasts during the testing of the aircraft.
Photo credit: Adrien Williams

The new aerospace campus marks a strategic leap forward from Bombardier's decades-old Downsview Airport facility, currently slated for redevelopment. The new Bombardier facility's production layout enables faster aircraft assembly with complete lines of sight throughout the manufacturing and testing processes. NEUF created an architecture that successfully coordinates specialized teams, automated equipment, robotics, tooling and the mobilization of precision components and instrumentation, resulting in an efficient, accurate and safe production ecosystem where employees work in natural daylight environments with minimal acoustic distractions. Precise electrical, ventilation, thermal and humidity requirements necessitated a manufacturing strategy that optimizes energy use while reducing waste to align with Bombardier's commitment to environmentally responsible operations. Extensive site engineering was required to incorporate a comprehensive list of fire and life safety requirements within a small, tightly regulated site that minimally impacts neighbouring airport-related services and municipal infrastructure. The NEUF design team led a complex collaboration with the Greater Toronto Airports Authority (GTAA), TÜV SÜD Global Risk Consultants, the City of Mississauga, Transport Canada, and NAV Canada to ensure the facility met the industry's most stringent fire, life safety, and flight operations standards.

: The new Bombardier campus is situated alongside Canada’s busiest runway at Toronto Pearson International Airport. Photo credit: Adrien Williams

: The new facility features some of the widest aviation doors in the industry, requiring advanced structural engineering and safety protocols. Photo credit: Adrien Williams

: An exterior view of the Aero-Structural Facility (ASF) and adjacent Flight Test Hangar (FTH). Photo credit: Adrien Williams

: As multimillion-dollar jets come to life, NEUF designed all aspects of this 24-hour aerospace manufacturing ecosystem to enhance employee morale and wellbeing. Photo credit: Adrien Williams

: Minimal travel distances between workstations, offices, and the production floor increase efficiency and contribute to employee interaction and sociability. Photo credit: Adrien Williams

: The aero-structural facility’s 246-foot (75-metre) clear spans enable complete lines of sight throughout the manufacturing and testing processes. This achievement allows a continuous production flow of aircraft, dramatically increasing the speed of assembly. Photo credit: Adrien Williams

: NEUF produced an architecture that successfully coordinates specialized teams, automated equipment, robotics, tooling, and the mobilization of precision components and instrumentation, resulting in an efficient, accurate, and safe production ecosystem. Photo credit: Adrien Williams

: From specialized trenches and floor design to ample daylighting, integrating innovative design and materiality optimizes the manufacturing processes of Bombardier’s jet aircraft. Photo credit: Adrien Williams

As multimillion-dollar jets come to life, NEUF designed all aspects of this 24-hour aerospace manufacturing ecosystem to enhance employee morale and wellbeing, not just their safety. Abundant natural light, dedicated training and collaboration spaces, and visual connections across various functions boost employee motivation and productivity. Minimal travel distances between workstations, offices, and the production floor increase efficiency while contributing to employee interaction and sociability. With a 50-year track record designing industry-specific and complex technology-based projects, NEUF brought their unique expertise and tested design processes to create the latest aerospace manufacturing.

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Inspired by flight: the Bombardier office reception area incorporates wing-shaped baffles overhead and a floating desk set within an abstracted cloud.
Photo credit: Adrien Williams

: The testing and finishing of Bombardier’s flagship Global 7500 jet aircraft. Photo credit: Adrien Williams

: A Global 7500 goes through a testing process, requiring extensive overhead ventilation and fire safety controls, with comprehensive underfloor services. Photo credit: Adrien Williams

: Careful attention is paid to ensuring that the aircraft’s most valuable component—its jet engines—is precisely integrated with the fuselage and wings. Photo credit: Adrien Williams

: NEUF integrated the largest overhead doors in the industry into the new testing facility, where several planes can safely enter and leave in preparation for interior finishing and painting at Bombardier’s Montreal factory before final delivery to the client. Photo credit: Adrien Williams

: The testing and finishing of Bombardier’s flagship Global 7500 jet aircraft. Photo credit: Adrien Williams

: The testing and finishing of Bombardier’s flagship Global 7500 jet aircraft. Photo credit: Adrien Williams

: Dedicated training and collaboration spaces maximize daylight and visual connections to promote employee motivation and productivity. Photo credit: Adrien Williams

: Controlled entry access for employees features a floating artificially illuminated ceiling and contrasting materials to facilitate movement and orientation. Photo credit: Adrien Williams

About NEUF

Founded in Montreal in 1971, NEUF architect(e)s has grown into one of the largest and most diversified architecture and design firms in Canada. With offices in Montreal, Ottawa and Toronto, the award-winning practice is built around long-lasting client relationships and engaged employees. This collaborative approach has led to the successful completion of over 8,000 projects across the globe. NEUF is well known for delivering exceptional design service in many practice areas, helping build a richly diverse portfolio of work for key Canadian institutions, leading real-estate developers, and cutting-edge manufacturing buildings for international market leaders.