NHYTE project aims at developing concepts and methodologies which will enable the realization of innovative and green integrated aero-structures made by a new recyclable hybrid thermoplastic composite material with multifunctional capabilities. The new composite material answers to the need for reduced weight and consequently reduced fuel consumptions and emissions of an aircraft, as well as for more ecological and less costly manufacturing processes. This material will be fabricated by an innovative working cell implementing advanced and continuous automated production processes. Typical aero-structure made by using the new NHYTE material will be manufactured by robotic machine using new processes as: “In-Situ Consolidation Automated Fibre Placement (ISC AFP)”,“Continuous Compression Forming (CCF)” and will be assembled by “Induction Welding (IW)”. This concept on one side will provide advantages from the structural point of view, in terms of better impact damage performance, while on the other side major advantages will result on manufacturing process simplification, including improved cycle times and lower energy consumptions, since it does not require autoclave for consolidation phase. The proposed manufacturing technology has wide spectrum of applications, not confined to a certain typology of components. The generic nature, in fact, makes the processes proposed in this project suitable and profitable for other business areas, not only aerospace field. The ISC of thermoplastic materials by AFP process is an attractive manufacturing technology as it is fast, clean, automated and uses sustainable materials. Specific market opportunity will be explored for the innovative products investigated during the project, including hybrid material production, panel fabrication and composite assembly by welding, together with the final goal of design, production and certification of primary aircraft structure.
