PRODUCTION OF THE THERMOPLASTIC COMPOSITE UPPER SHELL FOR THE MFFD

The CleanSky II Multifunctional Fuselage Demonstrator (MFFD) is the world’s largest known aviation structure manufactured from 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 eight-meter long upper half shell. The process chain of this crown shell is based on different thermoplastic technologies for single part manufacturing and automated assembly, developed and matured by the respective project partners. The skin laminate manufacturing was conducted by in-situ automated fiber placement. Subsequent stringer integration was performed by robot-based continuous ultrasonic welding. Integral C-frames, frame-couplings and cleats were integrated by electrical resistance welding using a carbonfiber fabric-based implant and a unique customized automation process. All mentioned production technologies represent major opportunities for a sustainable aviation of tomorrow with a low footprint production system. Intense process development on coupon level was performed prior to verification of the respective technology bricks on a full-scale upper shell with single-aisle dimensions. Thus, successful validation of design principles for a thermoplastic fuselage, its lean manufacturing and dustless joining technologies were achieved