World's Largest CFRTP Airframe Successfully Manufactured and Assembled
In a recent breakthrough, the Fraunhofer Institute for Manufacturing Engineering and Applied Materials Research (IFAM), in conjunction with its partners, has announced the completion of the thermoplastic composite airframe demonstrator (MFFD). This marks a significant milestone with the joining of the upper and lower sections of the airframe, measuring 8×4 meters, and the subsequent integration with the cabin top module at the Center for Applied Aeronautical Research in Hamburg, Germany.
The MFFD stands as the world's largest carbon fiber-reinforced thermoplastic composite (CFRTP) aircraft component, showcasing an automated manufacturing approach for thermoplastic composite airframes at a 1:1 scale. The materials and techniques employed in this initiative are designed to reduce the structural weight by approximately 10% and lower costs by a similar margin during rapid production processes.
As part of the "Smart Multifunctional Integrated Thermoplastic Composite Airframe" (STUNNING) project, the thermoplastic composite lower airframe shell was cured under high temperature and pressure conditions using an autoclave. This process was carried out by a collaborative team including GKN Fokker, Diehl Aviation, the Netherlands Aerospace Center (NLR), and Delft University of Technology.
The upper airframe shell was fabricated using fiber tape laying and in-situ consolidation processes, led by a consortium consisting of Premium Aerotec, Airbus, Aernnova, and the German Aerospace Center. Both the upper and lower shells are highly pre-integrated, featuring a design with minimal rivets, which results in a 10% weight reduction compared to conventional airframes.
Following the successful "Automated Cabin and Cargo Lining Assembly Methods" (ACCLAIM) project in 2021, which featured an automated cabin assembly platform at a 1:1 scale, the MFFD represents the second major Clean Sky 2 demonstration project to which the Fraunhofer Institute has contributed significantly. The MFFD thermoplastic composite airframe components have been shipped to the Center for Applied Aeronautical Research (ZAL) in Hamburg, Germany, for the final integration of the cabin top module. The fully assembled component will then be utilized for further testing and validation processes.
