MFFD – Production Technology for the Thermoplastic Fuselage of Tomorrow

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Welding bridge for integration of the rib by means of resistance welding
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Welding bridge for integration of the rib by means of resistance welding

Credit: DLR (CC BY-NC-ND 3.0).
In-situ gelegtes Testpanel mit ultraschallgeschweißten Stringern Airbus
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In-situ gelegtes Testpanel mit ultraschallgeschweißten Stringern in AIRBUS A320 Dimension (vollmaßstäbliche Halbschale)

Credit: DLR (CC BY-NC-ND 3.0).
In-situ gelegtes Testpanel von AERNNOVA
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In-situ gelegtes Testpanel mit ultraschallgeschweißten Z-Stringern von AERNNOVA

Credit: DLR (CC BY-NC-ND 3.0).
CleanSkyII Konsortium zur Herstellung der 8m langen Oberschale
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CleanSkyII Konsortium zur Herstellung der Oberschale

Credit: DLR (CC BY-NC-ND 3.0).
Multitow Legekopf für die laserbasierte in-situ Konsolidierung der Flugzeugaußenhaut
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Multitow Legekopf für die laserbasierte in-situ Konsolidierung der Flugzeugaußenhaut

Credit: DLR (CC BY-NC-ND 3.0).
End-Effektor zum roboterbasierten, kontinuierlichen Ultraschallschweißen
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End-Effektor zum roboterbasierten, kontinuierlichen Ultraschallschweißen der Stringer

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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CAD-model of the fiber placement process within the multifunctional robot cell at DLR-ZLP

Credit: DLR (CC BY-NC-ND 3.0).
Bild 8
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Bild 8

Credit: DLR (CC BY-NC-ND 3.0).
Bild 9
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Bild 9

Credit: DLR (CC BY-NC-ND 3.0).
Flashlamp based Automated Fiber Placement (F-AFP) for in-situ consolidation
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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).

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 involved in the development of future-oriented, laser-based in-situ consolidation, advanced fibre placement (AFP), as well as the further development of 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 319874-1053

Current work on test shell - MFFD project