First curved ultrasonic welds

What we achieved: we have conducted successful experiments to join thermoplastic composite parts that have a curvature representative of applications in lightweight composite structures. The first of many steps, parallel to ongoing scientific research on improving and scaling up this technology.

We are welding in the axial direction with a non-planar weld overlap. The current work focused on validating our specialised weld tooling and process control methods to achieve high-quality and repeatable welded joints within controlled conditions in our lab. In the coming months, we will continue to finalise two demonstrators, each depicting relevant use-cases for the aerospace industry.

The next steps in the future: welding of seams in the circumferential direction. In parallel projects, we are conducting in-depth research on optimizing the quality and robustness of non-planar welding for various applications and material combinations.

Why this is relevant?

In the manufacturing industry, hardly any surface is perfectly flat. We are developing smart and autonomous robotic solutions to manufacture structures with a large variety of geometric challenges and complexity.

Read more about our project  – part of the “Aerospace in transition” programme.

If you want to collaborate to achieve mutual success, feel free to contact our business developer Aydin van den Bergh.