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Aerospace manufacturing innovations demonstrate the future of aerocomposites

CAMX 2025: Attendees are able to explore several of NIAR ATLAS’ prototype developments in person, highlighting tool-less space manufacturing, AI-enabled inspection and repair and thermoplastic overmolding.

Grace Nehls
Edited by:  Grace Nehls
Senior Managing Editor, ÂÌñÏ×ÆÞ and Products Finishing

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Source (All Images) | NIAR

The National Institute for Aviation Research (NIAR) Advanced Technologies Lab for Aerospace Systems (ATLAS) invites CAMX attendees to experience the future of aerospace manufacturing. This year’s exhibit features demonstrations of advanced automated processes, including tool-less manufacturing in space, AI-enabled inspection and repair, and next-gen thermoplastic overmolding.

A key highlight is a complex thermoplastic rib structure developed for the tip rib of an eVTOL V-tail. Manufactured using a fully automated hybrid overmolding process, the rib showcases how NIAR is transforming traditional fabrication. By combining thermoforming of continuous fiber-reinforced substrates with injection molding, the process eliminates the need for subtractive machining and multipart assembly. The result is a high-performance, lightweight component produced in just 2 minutes — compared to the 80-100 hours required to machine its metal counterpart — while also delivering a 30% weight reduction.

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Front and back of the eVTOL tail tip rib.

The NIAR ATLAS team also showcases full-scale demonstrators and process simulation data at the booth, revealing how digital design and integrated automation are accelerating aerospace innovation. Developed in collaboration with industry leaders including Joby Aviation, KraussMaffei, Toyota, Victrex and Prospect, the project illustrates how proven technologies from automotive and medical sectors can be de-risked and rapidly adapted for aerospace and defense applications.

According to NIAR, this advanced process supports lean, high-rate production with improved material efficiency, reduced energy use and high repeatability. It also reflects NIAR ATLAS’ broader mission to enable cost-effective, scalable solutions for both aerospace and defense sectors.

In addition to the rib structure, NIAR displays:

  • Tool-less in-space manufacturing concepts using in situ thermoplastic consolidation
  • A single-piece serpentine duct created with a melt-out tool approach
  • AI-enabled automated inspection and repair technologies designed for future smart factories.

Each innovation has been developed with partners across aerospace and automotive sectors.

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