MFFD – Production Technology for the Thermoplastic Fuselage of Tomorrow

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Xenon flashlamp-based lay-up head
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Credit: DLR (CC BY-NC-ND 3.0).
Flashlamp based Automated Fiber Placement (F-AFP) for in-situ consolidation (ISC)
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Credit: DLR (CC BY-NC-ND 3.0).
Consortium for the thermoplastic upper shell
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Credit: DLR (CC BY-NC-ND 3.0).
8m full-scale thermoplastic fuselage upper shell demonstrator with focus on manufacturing and assembly
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Credit: DLR (CC BY-NC-ND 3.0).
Frame, cleat and clip integration by fully-automated resistance welding
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Credit: DLR (CC BY-NC-ND 3.0).
CAD-model of the fiber placement process within the multifunctional robot cell at DLR-ZLP
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Credit: DLR (CC BY-NC-ND 3.0).
CAD-model of the stringer integration by continuous ultrasonic welding
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Credit: DLR (CC BY-NC-ND 3.0).

The Center for Lightweight Production Technology in Augsburg (ZLP-AU) together with Premium Aerotec and Aernnova will deliver the eight metre long upper half shell for the next-generation fuselage demonstrator made of carbon fibre-reinforced thermoplastics.

The full-scale multifunctional fuselage demonstrator (MFFD) is one of the major flagship demonstrators within the greater European Clean Sky 2 Large Passenger Aircraft (LPA) project.

“[T]he Large Passenger Aircraft goal is both the high-TRL demonstration of the best technologies and the development of disruptive technologies for '2035+' applications to accomplish the combined key ACARE goals with respect to the environment, fulfilling future market needs and improving the competitiveness of Europe’s aeronautical industries.”
https://www.cleansky.eu/large-passenger-aircraft

In this context, DLR ZLP is concerned with the development of cutting-edge in-situ advanced fibre placement (AFP) with a novel flashlamp heating system, as well as the maturation of the welding technologies – especially continuous ultrasonic welding and resistance welding – for dust-free final assembly.

DLR is developing the technologies today to enable tomorrow's zero-emission flight.

Contact

Dr Frederic Fischer
German Aerospace Center (DLR)
Institute of Structures and Design, , Center for Lightweight Production Technology
Augsburg
Tel.: +49 821 319874-1046

Dr Lars Larsen
Head of group
German Aerospace Center (DLR)
Institute of Structures and Design, , Center for Lightweight Production Technology
Augsburg
Tel.: +49 821 319874-1031