Digitalising composite repair technologies

Kurzfassung

The GENEX consortium's final event (Zaragoza, 17 Feb 2026) presented a digital‑first approach to composite‑structure repair, targeting the long‑standing drawbacks of conventional scarf‑bonded repairs (high complexity, lengthy labour, cost, and stringent regulatory constraints). The project’s core objective was to create new, digitally supported processes and tools for adhesively bonded scarf repairs.

Four technology modules were demonstrated.

Visual‑Assisted Scarfing (T4.1); a Zeiss ATOS 5 scanner with custom software that captures the damaged geometry, generates parametric repair designs, and projects cutting‑paths, thermocouple locations, and backing structures directly onto the part, thereby reducing manual errors and documentation effort.

Portable LIBS Cleaning System (T4.2); a mobile Laser‑Induced Breakdown Spectroscopy unit adapted for curved aircraft components, capable of rapid, in‑situ detection of surface contaminants (oil, grime) and integration with a laser‑cleaning station for immediate remediation. Online Heating‑Blanket Control (T4.3); an IoT‑linked, digitally‑twin platform that uses CFD‑derived fluid‑flow models and a reduced‑order algorithm to optimize blanket layout and adapt heating in real time, ensuring target cure temperatures while minimizing energy use. Smart Patch Repair (T4.4); a development path from PVDF‑based surface toughening to a TPU‑based patch equipped with embedded fibre‑optic sensors (FOSS) for crack detection and active crack‑stopping, though the final patch is still a learning outcome rather than a commercial product. Validation on an A400M VTP panel showed successful contamination detection, effective laser cleaning, and improved temperature control. The work aligns with EASA AMC 20-29 requirements for process‑controlled adhesive bonding and demonstrates how digital tools can streamline composite repairs, cut downtime, and enhance traceability through an integrated data‑management platform. Funded by the European Union (CINEA); authors: Dirk Holzhüter (DLR) and the GENEX consortium.