How to Produce a Thermoplastic Fuselage

The CleanSky II Multifunctional Fuselage Demonstrator (MFFD) is the world's largest known aviation structure made of thermoplastic composites. The Center for Lightweight Production Technology (ZLP) in Augsburg together with Premium AEROTEC, supported by Aernnova and Airbus are responsible for the delivery of the 8m long upper half shell. The process chain of this crown shell is based on in-situ automated fiber placement for the skin placement, continuous ultrasonic welding of the stringers and resistance welding of frames and cleats. All of these production technologies represent major opportunities, however, associated with a multitude of corresponding risks. The main aspects of the development were thus driven by risk mitigation. Intense process development on coupon level was performed prior to verification of the respective technology bricks on a fullscale test shell with single aisle dimensions, and followed up by detailed root cause failure analysis. Thus, successful validation of design principles for a thermoplastic fuselage, its lean manufacturing and dustless joining technologies were achieved