HEMERA

The joint research project HEMERA, funded by the German Federal Ministry for Economic Affairs and Energy (BMWi) under the framework of the German Aeronautical Research Programme VII-1, aims at the development and validation of manufacturing processes for large, singly curved and stringer-reinforced fuselage panels. The focus lies on the prototypical production of these panels using thermoset carbon fibre reinforced plastics (CFRP). The overarching objective is to enable fibre-reinforced composite structures for future high-rate aircraft production exceeding 70 aircraft per month, while realizing significant weight reduction potential. By the end of the project, the technological maturity of the developed processes will be increased and their suitability for industrial series production will be demonstrated.

To achieve the ambitious climate targets of the aviation sector, future aircraft generations must be designed and manufactured to be significantly lighter and more sustainable. Carbon fibre reinforced plastics (CFRP) offer substantial weight reduction potential in this context. However, existing manufacturing processes for large, stringer-reinforced fuselage shells are often too slow, cost-intensive, and energy-consuming to meet the targeted production rates of more than 70 aircraft per month. There is currently a lack of industrialized, highly automated process chains capable of enabling resource-efficient and low-tolerance manufacturing of CFRP panels within the required cycle times.

Within the joint research project HEMERA, DLR addresses the development of an innovative, high-rate manufacturing technology for CFRP fuselage segments. The focus lies on fully automated process chains for stringer-reinforced panels, designed to achieve short cycle times, high process stability, and resource-efficient production. Key technologies include fibre placement on convex male mould tools, the integration of stringers during skin lay-up, and subsequent co-curing into an integral, load-bearing structure.