On the Manufacturing and Assembly of the Multifunctional Fuselage Demonstrator`s Upper Shell

Abstract

The CleanSky II Multifunctional Fuselage Demonstrator (MFFD) is the world's largest known aircraft structure made from 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 eight-meter-long upper half-shell. The process chain for this upper shell is based on various thermoplastic technologies for individual part production and automated assembly, which were developed and optimized by the respective project partners. The skin laminate was produced by automated in-situ fiber placement. The subsequent integration of the stringers was carried out using robot-assisted continuous ultrasonic welding. Integral C-frames, frame-couplings and cleats were integrated by electrical resistance welding using a carbonfiber-based implant and a unique custom automation process. The aforementioned production technologies offer great opportunities for sustainable aircraft structure production and assembly through the use of energy efficient manufacturing processes. Before verifying the respective technology building blocks on a full-scale upper shell with single-aisle dimensions, intensive process development was carried out at coupon level. In this way, the design principles for a thermoplastic fuselage, its lean production and dustfree joining were developed. This publication focuses in particular on the technology bricks developed and applied at DLR`s Institute of Structures and Design.