During the first phases, process has been defined and small tests have been run in order to get confirmation of the design. After that, a simplified mock-up, incorporating all the key elements (skin, stringers, spar and stiffener), has been manufactured, following the full-scale process. After verification of the results, design and manufacturing of the full-scale system has been done and full scale dummies have been manufactured.
An agile methodology has been used, speeding up trial and error loops. Low cost dry fibre tape (<50% cost) and MTorres rapid mould manufacturing allowed more iterations and shorter cycles. MTorres has made use of previous experience to optimise AFP technology in order to maximise the wing box quality and minimize time and cost.
Simulations of the process have been done when needed (infusion, heat exchange, etc.), in order to verify process parameters and reliability.
Manufacturing system includes:
- Lightweight carbon fiber tooling for both wings (LH/RH).
- Vacuum-assisted preform transportation device
- ACTI, complete process control
- Hotforming, infusion and curing station
- Resin dosing system
- Non-contact flow and curing monitoring equipment
- AR equipment
MTorres AFP machine has been used for the process, including its cut and add system at full speed, ensuring this solution has been the highest productivity dry fibre placement solution. Infrared (IR) has been used to activate the binder, as it was suitable for the material used and had less safety requirements than laser.
Manufacturing of the portable production equipment, transportation to Topic Manager site, fast setup and manufacturing of 2 full-scale dummy parts, as well as aeronautical grade material demonstrators, have been successfully achieved. Parts show an extremely high degree of integration, which includes not only the skin and stringers, but also the front and rear spars, along with their stiffeners, everything infused one-shot but keeping the same tolerances that can be achieved in standard assembly jigs, when parts are individually positioned and fastened together.
Dissemination activities have been carried out, in order to show the advantages of this technology to end users. Workshops were held at TM facilities for the knowledge of engineers and designers. Information was also shown at composite trade fairs, like JEC.
