• Completed

Thermoplastics composite fuselage assembly

STUNNING

As part of aviation industry’s efforts to become more sustainable, SAM XL is developing a revolutionary, intelligent production system for assembling the lower section of an aircraft fuselage.

Thermoplastics composite fuselage assembly
DurationJanuary 2021 – December 2022
PartnersTU Delft, GKN-Fokker, NLR, Diehl Aviation

The aeronautical sector is a critical player in contributing to smart, green and integrated transport, as defined by Horizon 2020. Proper fuselage, cabins and systems integration technologies is considered one of the most viable opportunities that can offer a potential double digit (10%+) decrease of fuel burn and CO2 emission, as well as reducing NOX and noise emissions. STUNNING will address this opportunity by demonstrating the use of new and advanced thermoplastic materials, and manufacturing techniques in the fuselage assembly.

Multifunctional fuselage demonstrator

Render of the fuselage structure

The 8 meter long narrow-body airliner fuselage will integrate engineering, manufacturing, assembly and, overall technology maturation, targeting a significant increase of fuselage build rates, dramatically reduced recurring costs, as well as substantial weight reduction at fuselage level. At SAM XL the lower half-fuselage section is being assembled. This consists of integrating the skin, reinforcement stringers, cabin floor and a cargo structure.

SAM XL engineers are working on the following innovative techniques for this project:

  • Ultrasonic welding of fuselage structure
  • Stringer Robotic pick and place / automation of assembly
  • Advanced manufacturing process simulations
  • Simulation methods for virtual testing
Multifunctional fuselage demonstrator

Funding

This project has received funding from the Clean Sky 2 Joint Undertaking (JU) under grant agreement No 945583.

Funding

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