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Case StudyHELUES
Highly Efficient Production of Structural Aircraft Components
The production of aerospace structural components from thermoplastic UD tape laminates with injection-molded functional integrations offers great potential for cost and time savings. Through a one-step overmolding process, thermoforming and injection molding are combined, drastically reducing the number of individual parts and assembly steps. At the same time, a material bond is created between the materials, resulting in highly functional components with minimal process times.
Motivation
Reduction of cycle times, costs, and assembly steps through the use of thermoplastic instead of metallic or thermosetting materials
Approach
The use of thermoplastics in aviation opens up enormous potential for the industry. Due to their light weight, high strength, and the possibility of functional integration, components can be manufactured more efficiently and cost-effectively. This not only contributes to reducing production times but also improves the sustainability and performance of the components.
Motivation
Efficiency Increase in Component Manufacturing
The production of components from metals or thermosetting plastics is associated with long cycle times and many assembly steps. The use of thermoplastic materials such as PEKK-CF offers significant advantages: they enable shorter process times, reduce the number of individual parts and assembly steps, and facilitate automated manufacturing. Thus, highly complex components can be produced in the shortest time. PEKK-CF is characterized by high temperature and chemical resistance as well as excellent mechanical properties – ideal for aerospace applications.
Solution Approach
One-Step Thermoforming and Injection Overmolding Process
A one-step thermoforming and injection overmolding process allows for the direct connection of functional elements to a complex reshaped organosheet made of continuous carbon fiber reinforced PEKK-CF. The organ sheet is first thermoformed and then equipped with reinforcement structures and fastening elements in the same process step through injection molding. This eliminates additional joining processes such as gluing or riveting and ensures a material bond. The combination of both process steps significantly reduces manufacturing time and costs while simultaneously optimizing component quality.
Approach
Highly Complex Structural Components in Minutes
As a result, a process was developed in the HELUES project that allows for the production of complex aircraft structural components in a one-step thermoforming and injection overmolding process with cycle times of less than 3 minutes. This process was validated using a demonstrator component that represents an attachment part of an aircraft emergency exit door.
- Short cycle times: The developed process allows for the production of aircraft structural components in less than 3 minutes
- High complexity: Deformations in multiple dimensions as well as complex functional integrations can be combined in one step.
- Thermoplastic matrix material: Due to the thermoplastic nature of the matrix material, the components are weldable and recyclable
Project sponsor: Bavarian State Ministry of Economic Affairs, Regional Development and Energy | Funding code: LABAY110B
Partners: Christian Karl Siebenwurst GmbH & Co. KG, Hexcel Composites GmbH, Airbus Helicopters