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MAnufacturing of the lining panel using hYbrid technologies; Additive manufacturing, injection moulding and thermoforming

Periodic Reporting for period 1 - MAYA (MAnufacturing of the lining panel using hYbrid technologies; Additive manufacturing, injection moulding and thermoforming)

Reporting period: 2019-03-01 to 2020-02-29

MAYA project main objective is to develop innovative manufacturing routes integrating standard thermoplastic processes (injection moulding and thermoforming) and additive manufacturing to realize lining panels of fuselage to reduce to reduce weight, optimize costs and enhance the part performances.
First, the correct workflow of MAYA project in order to clarify the different manufacturing technologies to compare, the distinct scales of the specimens, and the way to follow for reaching a final solution has been defined. Next, the most suitable thermoplastic materials for connecting elements to other structures, in order to emphasize the advantages of a fully thermoplastic fuselage and lining have been identified and selected. On the other hand, the design of the bracket for Additive Manufacturing (AM) has started. Additionally, different AM technologies have been analysed and started to test. In parallel, the development of a combined processing for manufacturing linings and injection moulding of functional elements has been developed. Furthermore, different options of Injection Moulding (IM) have been analysed as discussed among all the partners and the TM. All of that has been supported by testing activities including characterization of material properties at coupon level, testing of small-scale demonstrators of the bracket, and finally evaluate the influence of process upscaling on the part properties by testing large-scale parts.
All the results of MAYA project will impact the process transition for low volume production of aerospace transition to thermoplastics in terms of cost and process performance. MAYA will add the possibility for industry 4.0 and fast R&D iteration or change of production with on-demand manufacturing and digital storage rather than physical one.