The main objective of the ADDAPTTA SEALS project will be to develop new concept seals for wing aerodynamic surface, with better performance than currently used and further advantages in terms of cost, time to market and maintainability of the aircraft. This will be achieved due to the benefits of additive manufacturing technologies and the usage of specific materials developed for this particular purpose.
In addition to improving the aerodynamic performance of the aircraft, the use of this technology for the manufacture of the seals provides another series of advantages, including an optimization in resources needed for manufacturing, in terms of personnel, energy needed, less need for tooling, etc. All this results in a minimization in carbon footprint.
Conclusion:
Additive manufacturing technologies and specific materials has been developed for this particular purpose. For achieving these ambitious targets, a number of particularly complex knowledge and expertise are needed, related to aeronautic design, additive manufacturing processes, elastomeric materials specifically formulated for additive manufacturing, and qualification of products under aeronautical standards. Hence, ADATICA Engineering, CSIC-ICTP and APPLUS Laboratories consortium was created.
The main activities carried out by CSIC-ICTP has been related to analyze the elastomeric materials compatible with 3D printing prone to be employed in the elaboration of aircraft seals and formulate printable materials that fulfils the mechanical, environmental and functional requirements defined by the Topic Manager of AIRBUS.
On the other hand, Adatica has developed seal design optimization for each seal to improve friction and aerodynamical performances.
Simultaneously, coupons have been manufactured for technology and material testing ensuring that the selected material and manufacturing technology fulfills with the mechanical requirements. Once tested by Applus+, seal coupons where manufactured to develop functional and qualification tests at Applus+ infrastructures.
Lastly, manufactured seals for the wing of FTB#2 Regional Aircraft Flight Demonstrator of AIRBUS have been tested and an optimization loop to improve manufactured seals have been carried out. It is important to note that, the results of all functional tests on the optimized designs have been satisfactory, confirming that seals manufactured using additive manufacturing technology are an interesting solution when fast design changes are required.
