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ÂÌñÏ×ÆÞ rounds up coverage of the MFFD project over the past decade. Now complete, the MFFD illustrates numerous processes and technologies for manufacturing primary aerospace structures using thermoplastic composites. 

Herone, Spiral RTC, Teijin Carbon Europe and Collins Aerospace Almere recycle A350 thermoplastic composite clips/cleats waste into rods for the all-thermoplastic composite Multifunctional Fuselage Demonstrator’s crown.

Fraunhofer IFAM and partners have completed left and right welds connecting the upper and lower fuselage halves and sent the 8×4-meter full-scale section to ZAL for integration with a cabin crown module and testing.

Thermoplastic composite upper and lower half shells for the Multifunctional Fuselage Demonstrator were welded using CO² laser over a total length of 8 meters.

Demonstrator’s upper, lower shells and assembly prove materials and new processes for lighter, cheaper and more sustainable high-rate future aircraft.

Building the all-thermoplastic composite fuselage demonstrator comes to an end with continuous ultrasonic welding of the RH longitudinal fuselage joint and resistance welding for coupling of the fuselage frames across the upper and lower halves.  

Composites-focused technocenter builds alliances for R&D in digital and sustainable technologies, additive manufacturing, TPCs, hydrogen and new technocenter development.

Outlined technology bricks — including foldable wings, more efficient engines and propulsion and composite materials — could support a planned single-aisle next decade, plus Airbus’s renewed commitment of a commercially viable H2 aircraft.

Eight-meter-long CFRTP fuselage skin was achieved via laser-heated in-situ consolidation, with stringers, frames and cleats to be welded.

Clean Sky project has delivered the 8 × 4 meter welded aerostructure component, aided by advanced thermoplastic composite technologies and smart robotics.