As part of the LuFo project ZEUS, IVW is working on the development of integral design concepts, simulation methods and manufacturing processes for thermoplastic (TP) fuselage components of the future, such as the thermoplastic door surround structure and thermoplastic profiles. The main innovation on the part of IVW is the development of the closed chain of component design, process simulation and process development including the validation of the design methods and processes using the manufactured verification structures. The novel integral design of the door surround structure exhibits high lightweighting potential through the implementation of a topology-optimized design and cost efficiency through the combination of fast tape laying and thermoforming processes as well as the integration of connecting and stiffening elements in one step (over injection + co-consolidation). Simulative design of the manufacturing process for thermoplastic profiles also enables quality improvements and allows continuous digitalization of the process chain. The planned process developments futher enable the application of local reinforcements and changes to the profiles at The project “LuFo-ZEUS – Zero Emission Aircraft with Sustainable Fuselage Concept and Technology” is funded by the Federal Ministry for Economic Affairs and Climate Action on the basis of a decision by the German Bundestag (funding reference 20W2106F). The project “Systematic Identification of Damage Mechanisms of Short Fibre Reinforced Thermoplastics under Fatigue Loading and Development of a Method for Time Efficient Determination of the High Cycle Fatigue Strength” is funded by Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) – 398483802. any point. In addition to technological innovations, the production of components with thermoplastic materials offers the opportunity to reduce the ecological footprint through resource-saving processes with low energy consumption and waste minimization. In addition, the digitalization of processes (digital twin, process simulation) offers a variety of approaches to scrap reduction, energy-related process optimization, and reduced tests and NDT inspections.