Project description
Production innovation will reduce the life cycle environmental impact of aerospace parts
Not all polymers are created equal. When it comes to end of life and sustainability, thermoplastic polymers have a distinct advantage over thermoset ones. As their name suggests, thermoset polymers are ‘set’ once they are cured – they cannot be melted and reformed – whereas thermoplastic ones can be remoulded, making them easily recyclable rather than requiring harsh chemicals and processing conditions. Thermoset resins and autoclaving have been the standard in aerospace composites. The EU-funded MAYA project is changing the rules of the game with innovative manufacturing approaches that will decrease the production time, weight, and costs of thermoplastic fuselage lining panels, at the same time enhancing performance.
Objective
The demand for composite materials in aerospace is increasing, mainly due to their high strength to weight ratio which will lead to lighter structures and fuel saving. Increased usage of thermosets, the main composite used in aerospace, raises new concerns about their end of life and environmental impact associated with long time-consuming and high cost intensive processes. For example, thermoset fuselage skins are mainly produced by gantry-mounted advanced fiber placement (AFP) machines and co-curing of stringers in a subsequent autoclave cycle. This increase the high cost already enhance by the production of carbon fiber material. To be able to compete with metal based, an alternative production process for structural parts of aircrafts could be demonstrated using the advantages of thermoplastics. Composite thermoplastic materials provide an interesting alternative to thermoset composite materials. They are thus adequate candidates against the current issues of relief and sustainable development especially in the field of transportation, energy, and construction.
MAYA project main objective is to develop innovative manufacturing routes integrating standard thermoplastic processes (injection moulding and thermoforming) combined with additive manufacturing to realize lining panels of fuselage to decrease the production time, reduce weight, optimize costs and enhance the part performances using thermoplastic materials. The high productivity rate of thermoplastic injection moulding associated to the design freedom of 3D printing will lead to an overall enhancement of the panels performances and manufacturing. MAYA will have direct impact on European aerospace industries through achieving its goals. The actives have been carefully planned in seven workpackages in duration of 24 months to ensure that maximum impact in terms of manufacturing and assembly cost and time, environmental carbon foot print, etc will be delivered to European aerospace industries.
Fields of science
- engineering and technologymechanical engineeringvehicle engineeringaerospace engineering
- natural scienceschemical sciencespolymer sciences
- engineering and technologymaterials engineeringcompositescarbon fibers
- engineering and technologymechanical engineeringmanufacturing engineeringadditive manufacturing
Programme(s)
Funding Scheme
CS2-IA - Innovation actionCoordinator
08225 Terrassa
Spain