Production of a Full Scale Demonstrator-Structure within the FP7 Project “Maaximus”

Abstract

The main objectives within the EU FP 7 project “Maaximus - More Affordable Aircraft through eXtended, Integrated and Mature nUmerical Sizing” are as follows: Highly-Optimised Composite Fuselage: • Enable a high-production rate: 50% reduction of the assembly time of fuselage section • Reduce the manufacturing and assembly recurring costs by 10% compared to the ALCAS equivalent reference • Reducing weight by 10%, compared to best available solutions on similar fuselage sections. Faster Development: • Reduce by 20% the current development timeframe of aircraft composite structures from preliminary design up to full-scale test • Reduce by 10% the non-recurring cost of aircraft composite structures from preliminary design up to full-scale test (ALCAS reference) Right-First-Time Structure: • Reduce the airframe development costs by 5% compared with the equivalent development steps in an industrial context

As demonstrator and validator structure a side shell with a pax door was chosen (see picture 1). The design refers to an actual aircraft with a wide body fuselage.

Within the project phase 2, the German Aerospace Center (DLR) as work package (WP) leader is responsible for the WP 7.6 “Manufacturing & Assembly”.