Project description
An innovative composite fuselage door and rapid manufacturing techniques support greener transport
Aircraft manufacturing is a very complicated process. Huge parts must be manufactured individually and joined with very high integrity. In the quest to reduce the weight of aircraft while enhancing the functionality and performance of the components, engineers are focusing on various parts, from the fuselage and wings to the doors. The EU-funded TOD project is optimising promising thermoforming and welding processes with the goal of demonstrating rapid manufacturing of a full-scale composite door and its validation within its surrounding structures. The manufacturing process will be supported by Industry 4.0 automation and online monitoring.
Objective
The Regional Aircraft IADP will bring the integration of technologies developed in phase one within the Green Regional Aircraft ITD to a higher level of complexity and maturity via two flying test-beds and three large integrated ground demonstrators. The overall goal of the TOD project is to demonstrate rapid manufacturability and validation of a full scale thermoplastic composite door including its surrounding, sub-structure for regional aircraft fuselage barrel. This will be achieved by a tangible step beyond the current state of the art of several thermoplastic manufacturing technologies, some of which are already implemented in other certified aircraft parts. 3 reputable European partners, with a very well-known track-record in their respectively area of expertise, aim to use their background to address the objectives set out in this project. The proposed approach include:
• Optimisation and validation of component manufacturing using thermoforming and, joining processes such as, Induction Welding and Resistive Implant Welding, which will enable light weighting by removal of mechanical fasteners.
• Take advantage of technology advancement in industry 4.0 automation and on-line monitoring to support higher production rate with high quality performances ( Zero defect) and roubust control.
Fields of science
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Programme(s)
Funding Scheme
IA - Innovation actionCoordinator
CB21 6AL Cambridge
United Kingdom