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DEVELOPMENT OF A MANUFACTURING PROCESS FOR THE PRODUCTION OF SMALL SIZE COMPLEX-SHAPED STRUCTURAL AIRCRAFT COMPONENTS

Objective

The manufacturing of plastic mouldings and assemblies is today dominated by low labour regions. This has led to a fall in the European SME market share for moulded components during the last 10 years. European SMEs within this segment need to develop more innovative products and manufacturing processes to be competitive in the market. One of the industries using increasing volumes of plastic and composite parts is the aircraft industry.

We propose to develop a novel manufacturing technology using the benefits of carbon fibre as reinforcement and a high performance thermoplastic as the matrix material utilising the high processing speed of injection moulding. The output of this project will be a new technology for making thermoplastic mouldings reinforced with inserted carbon fibre preforms. This will enable the aircraft industry to enhance functionality and reduce environmental impact through weight saving (replacing denser metal parts) leading to lower fuel consumption. The potential to use thermoplastic components that are easily recyclable provides an additional incentive.
The use of injection moulding as a relatively rapid production process will provide up to 30% cost reduction. The project offers European SMEs an opportunity to develop high value manufacturing capabilities that can compete with low labour cost economies.

We have identified the civil aircraft industry as the primary market for the new technology. We also expect to be able to produce lightweight advanced structural parts for the gas and oil, transport and automotive sectors. We estimate the market opportunity, by penetrating the primary market for the first five years after the project, is equal to €147M of revenue from sales and licensing of the technology. The initial market strategy will be to concentrate on the EC market, where the consortium has a strong market presence and a clear route to market through the partnership with Airbus.

Field of science

  • /social sciences/economics and business/economics/production economics
  • /engineering and technology/mechanical engineering/vehicle engineering/aerospace engineering/aircraft
  • /social sciences/economics and business/business and management/commerce

Call for proposal

FP7-SME-2012
See other projects for this call

Funding Scheme

BSG-SME - Research for SMEs

Coordinator

DENROY PLASTICS LIMITED
Address
Clandeboye Road
BT20 3JH Bangor
United Kingdom
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
EU contribution
€ 362 589
Administrative Contact
William Francis Trevor Kirkpatrick (Mr.)

Participants (5)

SISTEMAS Y CONTROL DEL MEDITERRANEO SL
Spain
EU contribution
€ 229 063
Address
Av Reina Sofia 63
30833 Sang Verde Murcia
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Juan Celdran (Mr.)
5M SRO
Czechia
EU contribution
€ 329 367
Address
Na Zahonech 1177
686 04 Kunovice
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Richard Pavlica (Mr.)
AIRBUS OPERATIONS LIMITED
United Kingdom
EU contribution
€ 23 967
Address
Pegasus House, Aerospace Avenue, Filton
BS34 7PA Bristol
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Philippa Rowe (Ms.)
THE UK MATERIALS TECHNOLOGY RESEARCH INSTITUTE LIMITED
United Kingdom
EU contribution
€ 9 485
Address
Middle Aston House
OX25 5PT Middle Aston
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Richard Baker (Mr.)
INSTITUTO TECNOLOGICO DE ARAGON
Spain
EU contribution
€ 4 125
Address
Maria De Luna 8
50018 Zaragoza
Activity type
Research Organisations
Administrative Contact
José-Ramón Valdés (Mr.)