Major breakthroughs in assembly technology & thermoforming!

One year into the AeroFusion project, we are proud of the first tangible results in the process of manufacturing lighter aircraft. Together with our partners, we are developing crucial knowledge for industrial application of continuous ultrasonic welding and thermoforming of thermoplastic composites.

We recently reached these milestones:

Thermoforming breakthrough

Cato Composites successfully developed their thermoforming process for high temperatures and pressed the first stiffeners from the high-performance thermoplastic composite CF/LMPAEK. The first stiffeners are now ready for welding development.

Novel welding control strategy

Delft University of Technology and SAM XL developed a new approach to control robotic continuous ultrasonic welding. We achieved high-quality welded seams, including a robust strategy for welding start and end sections.

First integrated success

TU Delft and SAM XL successfully welded the first stiffener produced by Cato Composites to a skin. A major success and a key step forward!

We believe the success is due to the collective awareness that these technologies will be a gamechanger. The dedication of all people involved is immense. Everybody has a passion for the technologies they work on. As partners, we motivate each other to get the best out of the technologies complementing each other and solving challenges together. We are achieving high-quality output. This is what collaboration is all about!

A big thank you to all partners for the enthusiasm and expertise:

  • Airbus and Composite Technology Center for industrial relevance, guidance, and application focus.
  • Toray Advanced Composites contributes with high-quality aerospace grade material development and supply, and processing expertise. They are advancing the understanding of thermal cycles on the material.
  • Cato Composites for developing high-temperature thermoforming.
  • Delft University of Technology and SAM XL are pushing robotic continuous ultrasonic welding to the next level, including circumferential stiffener welding.