Revolution in Aviation: Production of the Multifunctional Fuselage Demonstrator (MFFD)

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We proudly present the summary from the manufacturing and assembly processes of the all-thermoplastic #MFFD upper shell.
The Upper-Shell was built together with our dear partners Aernnova, Premium Aerotec and Airbus.
We would like to thank everyone involved, without whose continuous motivation, inspiration and team spirit this success would not have been possible.
These are the key facts of the demonstrator:
- In-Situ consolidated lay-up of the skin (53 km tape placed in total)
- Production of 44 compression molded Z-stringers by Aernnova
- Robot-based ultrasonic spot welding of stringers for pre-fixation, each 500 mm
- World`s first fully automated, robot-based continuous ultrasonic welding of 44 stringers
- Production of 24 compression molded C-frames and loose parts by Premium Aerotec
- Automated integration of 24 frames by resistance welding (~300 welds)
- Automated integration of 12 frame-couplings by resistance welding
- Automated integration of ~158 cleats by cobot-based resistance welding (~316 welds)
Partner:
www.aernnova.com/
www.premium-ae...
www.airbus.com/
The Multifunctional Fuselage Demonstrator (MFFD) was developed as part of the Large Passenger Aircraft project and funded by the European Clean Sky-2 program.
www.clean-avia...
Funding:
This project has received funding from the Clean Aviation Joint Undertaking (CAJU) under grant agreement CS2-LPA-GAM-2020-2023-01. The JU receives support from the European Union’s Horizon 2020 research and innovation program.
More Information:
www.dlr.de/en/...

Опубликовано:

6 сен 2024

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Комментарии : 21

@SJR_Media_Group 3 месяца назад

Former Boeing Everett where 787 is made. We use huge rotating mandrels with AFP and ATL robotic heads robotically layers of carbon-fiber epoxy resin prepreg to contoured surfaces. Reinforcing fibers are oriented in specific directions to deliver maximum strength along maximum load paths. This produces and accurate copy of inside of fuselage. Demonstrator here actually makes a more dimensional accurate product. Using an inside mold produces exact dimensions of outside surface, which is very important.

@flyfree1935 3 месяца назад

Just a notice - big conceptual diff here it's all thermo-plastic - making the base wall and welding parts together. vs. thermo/chem sets. and riveting. No autoclave baking required either.

@SJR_Media_Group 3 месяца назад

@@flyfree1935 Thanks for comment.... yes no autoclave or even bagging parts under vacuum.

@NareshSharma-sm1kp 3 месяца назад

Congratulations, what an awesome result of your project. I would love to see biangled layup based laminate though! Congrats again.

@dlrinstituteofstructuresan6594 3 месяца назад

Thank you very much! The demonstrator certainly has further potential for optimization in some areas. The stacking sequence of the skin laminate was in fact specified in the project and was merely adapted to the boundary conditions of a production-orientated design. Our focus was on maturing processes undergoing technological development and demonstrating them on a large scale. This made it possible to identify technological opportunities, limits and development potential in many areas.

@id1568 3 месяца назад

The lander of Comet Philae was a success!

@hafizuddinmohdlowhim8426 3 месяца назад

Do you also made this available for commercial?

@abdokorayem9478 3 месяца назад

Looks amazing ... What is your matrix material and what are you using as a heater? Also are there any publications to read more in detail about this work?

@dlrinstituteofstructuresan6594 3 месяца назад

Material: Toray CF/LM-PAEK For the In-Situ Tape Lay-up process we are using a Laser as heating source. You can find more Information on our website: www.dlr.de/en/latest/news/2023/03/mffd-thermoplastics-instead-of-aluminium-in-aircraft-construction And in this article: www.compositesworld.com/articles/manufacturing-the-mffd-thermoplastic-composite-fuselage

@abdokorayem9478 3 месяца назад

@@dlrinstituteofstructuresan6594 Thank you and keep up the great work 👍🏻

@dixon_est 3 месяца назад

Nice project, but the background music is just awful.

@crapisnice 3 месяца назад

Thats not for an airplane but for a petrol rocket with wings, while a airplane ( an aircrfat that can plan, sail and soar by their own) can be built with flexible fabric covering with hemp fabric and a frame of recycled wood, cardboard and metal sheet And it would be 30-50% lighter compared to composite shell fabrication

@dlrinstituteofstructuresan6594 3 месяца назад

Thank you for your comment! There are many different design concepts for manufacturing an aircraft structure. Which of these concepts ultimately finds its way into application naturally depends on various factors. A mix of materials can certainly be expedient here. We use the term "Best Eco-Mix", which intends to evaluate the build concept from production through operation to recycling. (Manufacturing and assembly processes would also be required for the use of hemp fibers and recycled wood... this is where we feel at home)

@ntal5859 3 месяца назад

The first planes were made of carbon(wood) and fabric and glue... now they are trying to sell this as new innovative.

@kadir801 3 месяца назад

vay amk

@svendittmann3105 3 месяца назад

made by hand?!

@awfsdgyjuymghmn7241 3 месяца назад

Purposefully overlooking the performance difference between the first planes and modern aircraft is a real 🤡moment. This may not be a giant innovative step like developing all-metal monocoques or jet engines, but it's definitely another incremental step forward.

@slevinshafel9395 3 месяца назад

its me or its overenginered? any test and comparation versus isogrid fuselage?

@crapisnice 3 месяца назад

Rather little engineered, because fiber orientation can be applied with topology optimization or other softwares as in the north sails 3d sails That would be "over engineered" or the only reason to use machines

@user-zl6we3nf7k 3 месяца назад

Медную сетку забыли как Статик снимать и не ремонта пригодна заплату ни поставиш

@dlrinstituteofstructuresan6594 3 месяца назад

Thank you very much for your comments! The design of the upper shell was one of the specifications given in the project. It is certainly possible to make the upper shell even lighter by optimizing the topology. In this project, however, the focus was not on optimizing the upper shell structure but rather on maturing various manufacturing and joining technologies which, among other things, should make it possible to meet the rate capability requirements in aircraft production.