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Full-Scale Application of in-situ Automated Fiber Placement for the Production of a Fuselage Skin Segment

Deden, Dominik and Brandt, Lars and Mayer, Monika and Henning, Dietfried and Hellbach, Olivia and Fischer, Frederic (2023) Full-Scale Application of in-situ Automated Fiber Placement for the Production of a Fuselage Skin Segment. SAMPE Europe 23 Conference, 02.-05. Okt. 2023, Madrid, Spanien.

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Abstract

The CleanSky II multi-functional fuselage demonstrator 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 was responsible for the delivery of the 8 m long upper half shell. The first step in the upper shell production is the skin placement which is done by means of in-situ automated fiber placement (in-situ T-AFP). The process is a lean, single-stage additive manufacturing process for thermoplastic CFRPs. In order to ensure a sufficient quality in the laminate the ZLP has worked intensively on dedicated design principles for the process, material quality requirements and an optimization of process parameters. Major advancements on the way towards a full-scale fuselage have been displayed in the past by the manufacturing of a scaled demonstrator. This paper presents the evolution to the recently manufactured full-scale component with a total length of 8 m, a diameter of 4 m and a composite part design that includes reinforcements for the door cut-outs and two different welding interfaces. The latter will be leveraged for the joining of two half-shells by means of thermoplastic welding. In this work the methodology for a scale up to an actual airplane geometry and the associated challenges are emphasized. Critical aspects of the scale up and potential mitigation of future issues for in-situ process are discussed with regards to design, process and manufacturing. Finally, a way towards industrial, full-scale productions by means of in-situ AFP is proposed.

Item URL in elib:https://elib.dlr.de/199804/
Document Type:Conference or Workshop Item (Speech)
Title:Full-Scale Application of in-situ Automated Fiber Placement for the Production of a Fuselage Skin Segment
Authors:
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Deden, DominikUNSPECIFIEDhttps://orcid.org/0000-0001-8959-8720UNSPECIFIED
Brandt, LarsUNSPECIFIEDhttps://orcid.org/0009-0007-8608-0759147776144
Mayer, MonikaUNSPECIFIEDhttps://orcid.org/0000-0002-4448-9501147776146
Henning, DietfriedUNSPECIFIEDUNSPECIFIEDUNSPECIFIED
Hellbach, OliviaUNSPECIFIEDUNSPECIFIEDUNSPECIFIED
Fischer, FredericUNSPECIFIEDhttps://orcid.org/0000-0001-5421-4336UNSPECIFIED
Date:October 2023
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Published
Keywords:Aerospace, Fuselage, CFRP, Manufacturing Technologies, Automated Fiber Placement (AFP), Thermoplastics, in-situ consolidation, Scale-up
Event Title:SAMPE Europe 23 Conference
Event Location:Madrid, Spanien
Event Type:international Conference
Event Dates:02.-05. Okt. 2023
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 - Structural Materials and Design
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design > Automation and Production Technology
Deposited By: Deden, M.Sc. Dominik
Deposited On:30 Nov 2023 09:40
Last Modified:30 Nov 2023 09:40

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