Construction and Manufacturing

NLR Fibre Placement Machine
Construction and Manufacturing

25 February 2025

Space structures and materials

NLR offers comprehensive expertise in designing, testing, and manufacturing innovative space structures, including satellite backbones, instrument platforms, and launcher components. From design verification and prototype manufacturing to inspection, environmental testing, and integration of functions such as thermal management and antennas, NLR’s capabilities also extend to smart structures, enabling the creation of lightweight, high-performance space systems. […]
Development of AM-propellant tanks for use in satellites
Construction and Manufacturing

27 November 2024

R&D case: Development of AM-propellant tanks for use in satellites

This research project aimed to develop additively manufactured propellant tanks using non-standard metals for use in ESPA and ESPA Grande-class satellites. The propulsion systems of Dawn Aerospace use self-pressurizing propellants, eliminating the need for helium pressurants and propellant management devices. This allows for flexible, custom tank designs without additional systems, making Dawn’s propulsion systems simpler, […]
SUSTAINair DEMO3 - skin fibre placement
Construction and Manufacturing

02 October 2024

R&D case: SUSTAINair

SUSTAINability increase of lightweight, multifunctional and intelligent airframe and engine parts SUSTAINair is addressing the major challenge of making aircraft more sustainable. The research project focused on new technologies, materials, manufacturing processes and systems to achieve a paradigm shift to a circular approach of aircraft design and manufacturing. Aircraft need to become more recyclable from design, […]
Construction and Manufacturing

25 September 2024

Whitepaper: Cold Testing has become hot

NLR heeft baanbrekende werk verricht aan geavanceerde koelsystemen voor materiaal- en structurele tests, waarbij temperaturen variërend van -55°C tot extreme temperaturen zoals -253°C zijn bereikt. De toekomstige doelen van NLR omvatten het testen van volledig schaalbare waterstoftanks, brandstofsysteem-componenten en waterstof-elektrische aandrijfsystemen zijn cruciaal voor het bereiken van netto-nul-emissies tegen 2050. De continue technologische vooruitgang en […]
Construction and Manufacturing

23 September 2024

Cold Testing has become hot

Pursuing the goals for achieving net-zero emissions by 2050, liquid hydrogen as an energy source is a promising solution. One of the big challenges is the extremely low temperature, close to absolute zero, needed to cool the hydrogen. NLR has pioneered advanced cooling systems for material and structural testing, and elaborates in a white paper […]
Construction and Manufacturing

29 May 2024

Automated Fibre Placement based manufacturing of the lower half of the skin fuselage (MFFD/STUNNING)

Advanced thermoplastic composite technology and smart robotics will significantly reduce weight and manufacturing cost of future aircraft with a high production rate. In April 2024, the European Clean Sky 2 STUNNING project was successfully concluded. GKN Fokker, NLR, Delft University of Technology and SamXLabs, have successfully manufactured and assembled by welding the 8m by 4m […]
Construction and Manufacturing

11 March 2024

R&D case: Advanced Laminar Flow tAilplane (ALFA)

Leading edge manufacturing by fibre placement with dry fibres and with prepregs The challenge The reduction of the CO2 emission is an important challenge for all industry and transportation sectors. To create a sustainable aerospace, several European research programmes are initiated within the Clean SKY 2 call. One of these programmes is titled Advanced Laminar […]
Construction and Manufacturing

04 March 2024

Whitepaper: Exploring Large-Scale Additive Manufacturing

Innovation has always been the driving force behind advancements in the aerospace industry. The pursuit of excellence in aerospace tooling must not be an exception as it plays a pivotal role in the overall efficiency of aerospace operations. The complexities and challenges inherent in Large-Scale Additive Manufacturing (LSAM) of aerospace tooling demand the collaborative efforts […]
Construction and Manufacturing

04 March 2024

Exploring Large-Scale Additive Manufacturing

Large-Scale Additive Manufacturing (LSAM) can deliver enhanced efficiency, cost-effectiveness and design flexibility for composites cure tooling for Aerospace applications. For a while now NLR operates its own LSAM setup with success and actively participates in various projects dedicated to exploring this process. In a whitepaper NLR addresses the complexities and challenges but it also elaborates […]