The Full-Scale Innovative Pressure Bulkhead (FUSINBUL) project under the EU's Clean Sky 2 program, funded by Horizon 2020, aims to develop and validate two advanced manufacturing processes to significantly reduce overall production costs and time for composite pressure bulkheads in regional aircraft. Recently, the project produced two full-scale 3.5-meter pressure bulkhead demonstrators for full-barrel testing and certification.
Led by Leonardo S.p.A. (Rome, Italy), the FUSINBUL consortium includes the Foundation for Composite Materials Research, Development and Application (Fidamc, Madrid, Spain) as project coordinator responsible for composite bulkhead manufacturing, along with Italian partners Metitalia, OMPM, and Sertec. Metitalia and OMPM handle detailed design and production of testing tooling and metal components, while Sertec manages preliminary tooling design and drawing release.
The team states the bulkheads will employ carbon fiber-reinforced plastic (CFRP) combined with advanced lamination techniques to enhance mass production capabilities.
Two manufacturing approaches are being implemented:
- Epoxy CFRP prepreg using co-bonding technology, where cured Omega stringers will be co-bonded with AFP-laid skins.
- Dry fiber CFRP with out-of-autoclave (OOA) liquid resin injection. Cured Omega stringers and AFP-laid skins will be separately infused then joined via riveting.
Tooling designs have been optimized for manufacturing processes and industrial requirements. A cast aluminum tool was developed through lost-foam casting - a process where molten metal vaporizes foam patterns held stationary by sand. A precision indexed split-seal system eliminates gaps or mismatches. The bulkhead demonstrators have been delivered to Leonardo's facilities for final assembly of ground test prototypes.
