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How to Produce a Thermoplastic Fuselage

Fischer, Frederic and Endraß, Manuel and Deden, Dominik and Brandt, Lars and Engelschall, Manuel and Gänswürger, Philipp and Mayer, Monika and Vistein, Michael and Schönheits, Manfred and Schuster, Alfons and Jarka, Stefan and Bauer, Simon and Hellbach, Olivia and Larsen, Lars-Christian and Kupke, Michael and Ferstl, Stefan (2022) How to Produce a Thermoplastic Fuselage. M3B GmbH, Bremen, Germany. ITHEC 2022, 6th International Conference & Exhibition on Thermoplastic Composites, 12 – 13 October 2022, Bremen, Germany. ISBN 978-3-933339-33-1.

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Abstract

The CleanSky II Multifunctional Fuselage Demonstrator (MFFD) is the world's largest known aviation structure made of thermoplastic composites. The Center for Lightweight Production Technology (ZLP) in Augsburg together with Premium AEROTEC, supported by Aernnova and Airbus are responsible for the delivery of the 8m long upper half shell. The process chain of this crown shell is based on in-situ automated fiber placement for the skin placement, continuous ultrasonic welding of the stringers and resistance welding of frames and cleats. All of these production technologies represent major opportunities, however, associated with a multitude of corresponding risks. The main aspects of the development were thus driven by risk mitigation. Intense process development on coupon level was performed prior to verification of the respective technology bricks on a fullscale test shell with single aisle dimensions, and followed up by detailed root cause failure analysis. Thus, successful validation of design principles for a thermoplastic fuselage, its lean manufacturing and dustless joining technologies were achieved.

Item URL in elib:https://elib.dlr.de/191203/
Document Type:Conference or Workshop Item (Speech)
Title:How to Produce a Thermoplastic Fuselage
Authors:
AuthorsInstitution or Email of AuthorsAuthor's ORCID iD
Fischer, FredericFrederic.Fischer (at) dlr.dehttps://orcid.org/0000-0001-5421-4336
Endraß, Manuelmanuel.endrass (at) dlr.dehttps://orcid.org/0000-0003-4133-0834
Deden, DominikDominik.Deden (at) dlr.dehttps://orcid.org/0000-0001-8959-8720
Brandt, LarsLars.Brandt (at) dlr.deUNSPECIFIED
Engelschall, ManuelManuel.Engelschall (at) dlr.deUNSPECIFIED
Gänswürger, Philippphilipp.gaenswuerger (at) dlr.deUNSPECIFIED
Mayer, MonikaMonika.Mayer (at) dlr.deUNSPECIFIED
Vistein, MichaelMichael.Vistein (at) dlr.dehttps://orcid.org/0000-0001-6998-0017
Schönheits, ManfredManfred.Schoenheits (at) dlr.dehttps://orcid.org/0000-0002-5646-2111
Schuster, AlfonsAlfons.Schuster (at) dlr.dehttps://orcid.org/0000-0002-7444-366X
Jarka, StefanStefan.Jarka (at) dlr.deUNSPECIFIED
Bauer, SimonSimon.Bauer (at) dlr.deUNSPECIFIED
Hellbach, OliviaOlivia.Hellbach (at) dlr.deUNSPECIFIED
Larsen, Lars-Christianlars-christian.larsen (at) dlr.dehttps://orcid.org/0000-0002-4450-8581
Kupke, MichaelMichael.Kupke (at) dlr.deUNSPECIFIED
Ferstl, Stefanstefan.ferstl (at) premium-aerotec.comUNSPECIFIED
Date:12 October 2022
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Volume:6
Editors:
EditorsEmailEditor's ORCID iD
Herrmann, Axelherrmann@faserinstitut.deUNSPECIFIED
Publisher:M3B GmbH, Bremen, Germany
Series Name:International Conference & Exhibition on Thermoplastic Composites
ISBN:978-3-933339-33-1
Status:Published
Keywords:Thermoplastic Composites, LM-PAEK, Automated Fiber Placement, In-situ Consolidation, Ultrasonic Welding, Resistance Welding, Clean Sky II, MFFD
Event Title:ITHEC 2022, 6th International Conference & Exhibition on Thermoplastic Composites
Event Location:Bremen, Germany
Event Type:international Conference
Event Dates:12 – 13 October 2022
Organizer:CONGRESS BREMEN & MESSE BREMEN M3B GmbH in cooperation with Faserinstitut Bremen e. V. (FIBRE)
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:Components and Systems
DLR - Research area:Aeronautics
DLR - Program:L CS - Components and Systems
DLR - Research theme (Project):L - Production Technologies, L - Structural Materials and Design
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design > Automation and Production Technology
Deposited By: Fischer, Frederic
Deposited On:29 Nov 2022 18:13
Last Modified:29 Nov 2022 18:13

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