The structure serves as a proof of concept for a load-path optimised fuselage section of the electrically powered composite aircraft MDA1 eViator, which is being developed in the SHOREliner project by a consortium led by MD Aircraft.
The implementation is based on a multidisciplinary design process, developed in cooperation with the Institute of Aircraft Design and Lightweight Structures (IFL) at TU Braunschweig. Already in the early design phase, the structure is specifically tailored to the characteristics and limitations of the AFP process. The topology optimisation carried out by the IFL first determines the optimal arrangement of the stiffening elements according to the structural loads. Based on this, the stiffening geometry is generated automatically, taking into account the process-related limitations of the AFP technology – a methodology that was researched and developed in the DFG project OptiFee.
Through the systematic formalisation of AFP manufacturing knowledge developed in the OptiFee project, manufacturable geometries can be automatically generated based on the technical parameters and capabilities of the AFP system used, without requiring simulative or experimental manufacturing studies as intermediate steps. This enabled the entire process from design to finished component to be completed in less than five weeks.
The manufacturing process is divided into several phases: After completion of the topology optimisation and geometry generation, the CFRP skin is first laid up on a tool using the AFP process. Subsequently, the CNC-milled, aerospace-certified foam cores for the omega stringers are precisely positioned and fixed using epoxy-based adhesive films. To ensure the required adhesion during the subsequent process steps, a special spray adhesive is applied to the surfaces of the foam cores. The CFRP cover layers of the omega stringers are then also applied locally to the prepared foam cores using the AFP process. The final curing process of the entire component takes place in the autoclave under defined pressure and temperature conditions in accordance with aerospace-specific manufacturing standards.
The successfully manufactured demonstrator component validates the newly developed methodology and emphasises the potential for integral, automatically manufactured and weight-optimised structural solutions in future aerospace applications. The insights gained in the projects provide a robust foundation for the further development of resource-efficient manufacturing processes for complex CFRP structures. The component was presented to a wide audience for the first time at Hannover Messe last week and is on display this week at AERO in Friedrichshafen.
The project OptiFee is funded by the German Research Foundation (DFG). The IFW would like to thank the DFG for the financial support for the realization of the project.
The project SHOREliner is funded by the Federal Ministry for Economic Affairs and Climate Action (BMWK) as part of the sixth civil aviation research program (LuFo VI-3). The IFW would like to thank the BMWK for its financial support in carrying out the project and the partners for their excellent cooperation.
Contact:
For further information, please contact Tim Tiemann, Institute of Production Engineering and Machine Tools at Leibniz Universität Hannover, on telephone +49 414 177638 207 or by email (tiemann@ifw.uni-hannover.de).
