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Light weight, impact resistant, canopy for fast compound rotorcraft

Periodic Reporting for period 2 - FastCan (Light weight, impact resistant, canopy for fast compound rotorcraft)

Reporting period: 2018-06-01 to 2019-07-31

The main objective of this project is to enhance the competitiveness of the European aviation industry on the international market place by enhancing and leveraging innovation capability across Europe's aeronautical sector, involving all actors across the full innovation chain.
The main consideration for KLK Motorsport and Gerg to join this project was to open up new market possibilities in the aviation industry. Our goal is to become an established and valued partner in the European market for the design, development and manufacturing of innovative aerospace components and systems.
This project should allow us to demonstrate our extensive experience and capabilities in the field of cutting-edge composite solutions from the concept stage to the finished product.
Introducing proven and innovative design and manufacturing technologies from different fields such as motorsport and the automotive world to the aviation industry can bring a competitive edge to the European market place.
The main objective for the design concept is to realise an innovative canopy structure with a total weight of less than 60 kg while simultaneously meeting the set requirements with regards to pilots view capabilities, structural demands (CS 29, WSPS), aerodynamic drag reduction and structural provisions.
The economical demands will be continuously monitored and optimised together with tooling and manufacturing experts from Gerg with regards to overall production costs.
Project Start to Baseline review
- Analysis of given canopy design and interface status from AH
- Development of canopy concept with higher integration and innovative manufacturing concept.
- Definition of tooling and layup concept
- Component testing for FEA material property validation
- Canopy design in compliance with the SSS and technical design requirements
- Interface definition of adjoining components incorporated and defined
- FEA bird model validation for CS29 bird strike simulation
- FEA stress analysis (operating load cases, bird strike, misuse load cases)
- Weight and CoG analysis

Baseline review to PDR
- Detail design of Canopy structure in compliance with the SSS and technical design requirements
- FEA optimisation of laminate structure for all load cases
- Further detailing and harmonization of interface definitions
- Detailed sizing hypothesis and model validation
- Weight and CoG analysis
- RC compliance analysis
- Quality and configuration management plan
Result: PDR passed with open actions

PDR to CDR
- Detail design of Canopy structure in compliance with the SSS and technical design requirements
- FEA optimisation of laminate structure for all load cases (static and dynamic)
- Manufacturing of test parts for bird strike tests
- Create and finalised SSDD
- Create stress substantiation report
- Specify manufacturing process and harmonize with AH
- Define materials and supplier
- Prepare documentation of all manufacturing steps
- ECO Design Report: Upstream LCA
Result: Fastcan held the CDR, closed all major actions until end of reporting period and passed the CDR successfully

- Tooling drop data released on the 21.06.19
This project should enable KLK/Gerg to optimise, mature and prove proprietary and innovative design processes and manufacturing technologies for new aerospace applications.
The goal is to provide a cutting-edge technologies demonstrator that successfully applies motorsport and automotive know how to the aviation industry.
This technology transfer serves to improve and complement existing industry procedures for structural CFRP components.
The goal is to design and manufacture lightweight fuselage components with higher function integration more economically and in a shorter time frame.
In the medium term the potential of this technology can be applied not just to individual components, but potentially to the complete airframe.
Canopy Structure including Nose, Radome and avionic bay beams