Construction and Manufacturing

Construction and Manufacturing

04 April 2023

R&D case: MovAbles for Next generaTion Aircraft (MANTA)

The objective was to manufacture three Ti-6Al-4V flaperon ribs by Direct Energy Deposition (DED). With conventional manufacturing processes, it can be very costly or even impossible to produce components with such complex shapes. However, DED is also challenging due to various features inherent in the design: bulky thin parts, asymmetric geometry, overhanging features etc. The main challenge was manufacturing all the structures with the minimum distortion and highest accuracy.

Construction and Manufacturing

10 February 2023

R&D case: STUNNING: the world’s largest known thermoplastic aircraft structures

The Clean Sky 2 Multifunctional Fuselage Demonstrator (MFFD) with its 8.5 meter long composite-made fuselage section with an approx. 4 meter diameter gives a glimpse of what a next-generation aircraft could be. This typical section of a single aisle aircraft fuselage is completely produced from thermoplastic. Now, Royal NLR’s STUNNING project is turning heads as the MFFD’s largest component, the 8.5 meter long lower fuselage skin, has been manufactured and delivered to the project partners.

NLR Fibre Placement Machine
Construction and Manufacturing

07 February 2023

One of the world’s largest thermoplastic aerostructures successfully completed

Advanced thermoplastic composite technology and smart robotics will significantly reduce weight and manufacturing cost of future aircraft. Now the Clean Sky 2 Thermoplastic Fuselage Demonstrator (MFFD) lower half has been delivered. At 8m by 4m it’s one of the largest known thermoplastic assemblies in the world. It allowed the project to investigate thermal and positioning effects during the manufacturing of these kinds of complex thermoplastic parts.

Construction and Manufacturing

23 January 2023

Need for energy efficient structures calls for more durable composite structures

Advanced composites are gaining ground in many areas, especially aerospace, automotive and renewable energies, as they are lightweight and help to save energy. What is still missing are accurate and fast pre-production methods to optimise the durability of such large-scale composite structures. The aim of the newly launched EU-funded project D-STANDART is therefore to develop efficient methods to model the durability of large-scale composite structures of any design under realistic conditions.

3D metal print - noise-reduction liner
Sustainability and Environment

20 January 2023

R&D case: Aircraft Noise Reduction Technologies and Related Environmental Impact (ARTEM)

In recent years, improving energy efficiency (i.e. fuel consumption) and emission reduction have led to increased engine sizes and bypass ratios. These modifications create a crucial noise issue due to the emission of low-frequency noise and the size and effectiveness limitations of the current noise-absorbing structures (liners).

Construction and Manufacturing

15 November 2022

How additive manufacturing is building the wings of tomorrow

Morphing structures that let components change from one shape to another and additive manufacturing for producing lightweight and complex structures are regularly highlighted as innovative technologies for the aviation sector; both of them will help achieve aviation’s goal of being climate-neutral by 2050. In the Clean Sky 2 project MANTA, these various innovations are being brought together to make the aircraft of tomorrow a reality.

3D scanner KUKA robot at NLR Marknesse
Construction and Manufacturing

26 October 2022

R&D case: Sustainable Cost Efficient High Performance Composite Structures

The SuCoHS project focusses on new structural concepts with novel multi-material composites to provide high resistivity against thermal, mechanical and fire loading. In order to achieve the project objectives for sustainable and cost-efficient high performance composite structures, the SuCoHS concept focusses on the three main topics: design, manufacturing and operation.ot grown.

Digital twin proces monitoring
Construction and Manufacturing

26 October 2022

R&D case: Digital Twins for automated composite manufacturing

The aerospace manufacturing and production industries are increasingly challenged to be more competitive, and do more with less. To be able to comply with higher production rates, affordability and constant quality, high levels of automation are required for current-day manufacturing processes. This results in more parts meaning more process data to control and keep track of while the number of operators at the production floor has not grown.