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PRODUCTION OF THE THERMOPLASTIC COMPOSITE UPPER SHELL FOR THE MFFD

Fischer, Frederic and Endraß, Manuel and Deden, Dominik and Brandt, Lars and Engelschall, Manuel and Mayer, Monika and Vistein, Michael and Schönheits, Manfred and Gänswürger, Philipp and Görick, Dominik and Schuster, Alfons and Jarka, Stefan and Bauer, Simon and Hellbach, Olivia and Schmorell, Demas and Larsen, Lars-Christian and Frommel, Christoph and Huber, Armin and Joos, Moritz (2023) PRODUCTION OF THE THERMOPLASTIC COMPOSITE UPPER SHELL FOR THE MFFD. DLRK 2023; Deutscher Luft- und Raumfahrtkongress, 2023-09-16 - 2023-09-21, Stuttgart. (Submitted)

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Abstract

The CleanSky II Multifunctional Fuselage Demonstrator (MFFD) is the world’s largest known aviation structure manufactured from 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 eight-meter long upper half shell. The process chain of this crown shell is based on different thermoplastic technologies for single part manufacturing and automated assembly, developed and matured by the respective project partners. The skin laminate manufacturing was conducted by in-situ automated fiber placement. Subsequent stringer integration was performed by robot-based continuous ultrasonic welding. Integral C-frames, frame-couplings and cleats were integrated by electrical resistance welding using a carbonfiber fabric-based implant and a unique customized automation process. All mentioned production technologies represent major opportunities for a sustainable aviation of tomorrow with a low footprint production system. Intense process development on coupon level was performed prior to verification of the respective technology bricks on a full-scale upper shell with single-aisle dimensions. 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/200851/
Document Type:Conference or Workshop Item (Speech)
Title:PRODUCTION OF THE THERMOPLASTIC COMPOSITE UPPER SHELL FOR THE MFFD
Authors:
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Fischer, FredericUNSPECIFIEDhttps://orcid.org/0000-0001-5421-4336UNSPECIFIED
Endraß, ManuelUNSPECIFIEDhttps://orcid.org/0000-0003-4133-0834UNSPECIFIED
Deden, DominikUNSPECIFIEDhttps://orcid.org/0000-0001-8959-8720UNSPECIFIED
Brandt, LarsUNSPECIFIEDhttps://orcid.org/0009-0007-8608-0759UNSPECIFIED
Engelschall, ManuelUNSPECIFIEDUNSPECIFIEDUNSPECIFIED
Mayer, MonikaUNSPECIFIEDhttps://orcid.org/0000-0002-4448-9501UNSPECIFIED
Vistein, MichaelUNSPECIFIEDhttps://orcid.org/0000-0001-6998-0017UNSPECIFIED
Schönheits, ManfredUNSPECIFIEDhttps://orcid.org/0000-0002-5646-2111UNSPECIFIED
Gänswürger, PhilippUNSPECIFIEDUNSPECIFIEDUNSPECIFIED
Görick, DominikUNSPECIFIEDhttps://orcid.org/0009-0008-0806-0936UNSPECIFIED
Schuster, AlfonsUNSPECIFIEDhttps://orcid.org/0000-0002-7444-366XUNSPECIFIED
Jarka, StefanUNSPECIFIEDUNSPECIFIEDUNSPECIFIED
Bauer, SimonUNSPECIFIEDUNSPECIFIEDUNSPECIFIED
Hellbach, OliviaUNSPECIFIEDUNSPECIFIEDUNSPECIFIED
Schmorell, DemasUNSPECIFIEDUNSPECIFIEDUNSPECIFIED
Larsen, Lars-ChristianUNSPECIFIEDhttps://orcid.org/0000-0002-4450-8581UNSPECIFIED
Frommel, ChristophUNSPECIFIEDhttps://orcid.org/0000-0002-3717-1087UNSPECIFIED
Huber, ArminUNSPECIFIEDhttps://orcid.org/0000-0002-5694-8293UNSPECIFIED
Joos, MoritzInstitut für Bauweisen und StrukturtechnologieUNSPECIFIEDUNSPECIFIED
Date:16 September 2023
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Submitted
Keywords:Thermoplastic Automated Fiber Placement, Resistance Welding, Ultrasonic Welding, Multifunctional Fuselage Demonstrator, Assembly, Quality Assurance, Automated Manufacturing and Assembly
Event Title:DLRK 2023; Deutscher Luft- und Raumfahrtkongress
Event Location:Stuttgart
Event Type:national Conference
Event Start Date:16 September 2023
Event End Date:21 September 2023
Organizer:DGLR
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
Institute of Structures and Design > Design and Manufacture Technologies
Institute of Structures and Design > Automation and Production Technology
Deposited By: Endraß, Manuel
Deposited On:21 Dec 2023 09:32
Last Modified:24 Apr 2024 21:01

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