Within Clean Sky 2 the design and manufacturing of the fuselage of new single aisle aircraft is investigated through a large, multi-functional fuselage demonstrator, see Figure 1. The main objectives of this demonstrator are to enable high production rates with a minimum of 60 aircraft per month and to reduce structural weight and recurring cost. The envisaged demonstrator shall validate high potential multi-functional combinations of airframe structures, systems, cargo and cabin technology concepts for the next generation fuselage and cabin, using advanced materials and innovative design principles.

One of the key innovations for the multi-functional fuselage demonstrator is the modular assembly of pre-equipped sub-assemblies, see reference [1] and [4]. To make a step in the design and manufacturing of such integrated multi-disciplinary fuselage sub-assemblies, including components of structures, systems, cabin and cargo, advanced materials and manufacturing methods are required. Thermoplastic composites and their highly automated fibre placement production techniques and advanced joining methods, offer the flexibility and efficiency that is needed for the production of much more pre-equipped sub-assemblies to enable the modular assembly process for the future aircraft production supply chain.

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[1] S.L. Veldman, P.J. Kortbeek, P.C. Wölcken, R. Herrmann, J. Kos, I. Fernandez Villegas, Development of a multifunctional fuselage demonstrator, Proceedings of Aerospace Europe Conference, Bordeaux, France, 25 February 2020 to 28 February 2020

[2] D. Otten, T.A. Weber, J.C. Arent, Manufacturing Process Simulation – On Its Way to Industrial Application, International Journal of Aviation, Aeronautics, and Aerospace Volume 5 Issue 2

[3] Dörr, Dominik &Brymerski, Wojciech& Ropers, Steffen &Leutz, D. &Joppich, T. &Kärger, Luise& Henning, Frank. (2017). A Benchmark Study of Finite Element Codes for Forming Simulation of Thermoplastic UD-Tapes. Procedia CIRP. 66. 101- 106. 10.1016/j.procir.2017.03.223

[4] W.M. van den Brink, J. Kos, W.J. Vankan, A.J. de Wit, Large carbon fibre reinforced thermoplastic fuselage manufacturing supported by virtual processing, NLR-TP-2020- 393, 7th Aircraft Structural Design Conference, 2020

[5] L. Paletti, W.M. van den Brink, Virtual manufacturing for composites, overview and status, Presented at the ISCM 2018, November 2018, Marknesse, Netherlands, NLRTP-2019-367

[6] Website: https://www.compositesworld.com/articles/thermoplastic-compositedemonstrators-eu-roadmap-for-future-airframes-, G. Gardiner, Thermoplastic composite demonstrators - EU roadmap for future airframes

[7] Website: https://www.sucohs-project.eu/news/sucohs-newsletter-no-3, SUCOHS EU project newsletter 3

[8] Website: https://www.vacuumlift.jp/eng/vac/m6075.html, VD M-6075 Fukoku Corp. Japan

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Published on 15/02/21
Accepted on 15/02/21
Submitted on 15/02/21

DOI: 10.23967/emus.2020.012
Licence: CC BY-NC-SA license

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