The aerospace industry urgently needs innovative methods to manufacture aircraft in a more sustainable way. Through experiments, we are researching how to efficiently combine lightweight materials with innovations in the adhesive and manufacturing processes.
The aerospace industry faces the challenge of making aircraft lighter, more energy-efficient, and more sustainable. This requires new design and manufacturing methods, with advanced materials and joining techniques playing a key role. Structural bonding offers significant potential in this area, enabling strong, lightweight structures while providing greater design flexibility than traditional fastening methods.
SUBSONIC short for “Sustainable Structural Bonding Technologies” is advancing the next generation of structural bonding for aerospace applications. While adhesive joints are already widely used, increaslingly stringent requirements for damage tolerance and crack propagation pose new challenges for design, production, and inspection. The project is therefore developing new knowledge, methods, and technologies to further increase the reliability and serviceability of structural adhesive joints. In addition, the project is exploring ways to improve and automate the bonding process and the combination of different lightweight materials.
As Fokker’s long-term R&D partner, SAM XL contributes expertise in automated manufacturing processes, robots and tooling selection, and the development of specialised end effectors. We also provide the experimental environment Fokker needs to evaluate new technologies and manufacturing concepts. Together, we help accelerate the development and industrial deplyment of aerospace innovations.
This project is funded bij the Ministry of Economic Affairs and Climate Policy, within the programme: “TopSector High Tech Vliegtuigmaakindustrie (TSH)”.
The manufacturing industry faces major challenges due to labor shortages, international competition and a growing demand for accuracy in robotised production. Together with our partner Do IoT Fieldlab, we are developing solutions with the latest wireless technologies.
Since our founding in 2018, we have focused on the aerospace industry. In 2026, we are expanding into the maritime, wind and offshore, and civil engineering. In addition, we are broadening our portfolio with new automated manufacturing processes such as drilling, milling, and cold spray.
In this project we are developing an AFP system to manufacture a structural shell for a business aircraft seat, with autonomous processes, closed loop control and improved cognitive ergonomics for machine operators
The aim: to industrialise composite wrap joints as a disruptive alternative to welded steel nodes in offshore wind foundations, addressing Europe’s urgent need for cost-competitive, rapid, and sustainable manufacturing.
The next generation of aircraft will need to reduce their CO₂ emissions in many areas. In this project, we are focusing on improving the leading edge of aircraft wings.
We are developing a new technology to bond different types of composites together. This hybrid technology bonds thermoplastic composites with thermosets. The aim is to make aircraft and other large structures lighter and more sustainable.
SAM XL is advancing new technologies for continuous ultrasonic welding and – together with partners – thermoforming of thermoplastic composites so they can be applied in industrial manufacturing of large, lightweight aircraft structures.
SAM XL develops smart robotic solutions for welding ship panels together. This is currently mainly done manually.
