ZEUS

Fiber-reinforced thermoplastic composites (TP-FRP) have many advantages over thermoset materials, including weldability and recyclability. They are therefore gaining increasing interest in the aerospace industry. As part of the LuFo project ZEUS, IVW is investigating the opportunities and challenges arising from the use of TP-FRP for aircraft structures. The feasibility of this field of application is being investigated by studying complex component designs and geometries. a new type of thermoplastic door frame structure and stringer profiles. The main task is the development of a closed process chain, supported by process simulation. IVW pursues a holistic approach that combines design concepts, simulation methods and manufacturing processes for thermoplastic fuselage components. The process combines tape laying, thermoforming, co-consolidation and overmolding. In addition to process simulation, topology optimization for the design is also used to optimize the results and determine suitable processing conditions. Furthermore, it is possible to combine simulations and real-time data acquisition to create digital twins of the manufactured parts and thus reduce processing trials. The results then make it possible to predict the quality of the final part, as all relevant processing and material parameters are stored and analyzed. The developed processing chain enables the application of local reinforcements and thickness changes in profiles by utilizing the bonding possibilities of thermoplastics.

The aim of this project is the development of thermoplastic structural components and suitable process technologies for high-performance aircraft structures as well as the digitalization of the process chain for quality prediction, forecasting and assurance.