TB-Rumpf – Technology Bricks for Future Thermoplastic Fuselage Configuration

As part of the TB-Rumpf project, the autoclave-free consolidation of thermoplastic laminates and resistance welding are being further developed and validated as technology bricks for future thermoplastic aircraft fuselages. The work is being carried out in collaboration with partners from the aerospace industry and further research institutes.

State of the art for the consolidation of large-area components made of continuous fiber-reinforced high-temperature thermoplastic, such as CF-PAEK, is autoclave consolidation. Through an optimized process setup and tailored process control, it is possible to achieve complete consolidation using only temperature and vacuum pressure. The use of self-heated molds or ovens can eliminate the need for an autoclave and thus generate cost advantages. TB-Rumpf aims to mature the process called VCT (Vacuum Consolidation Technique) and to determine the process limits in terms of maximum possible laminate thickness.  

The weldability of thermoplastic structures represents an essential aspect for the future use of this material group. Resistance welding in particular is characterized by high achievable strengths and is therefore of great importance for thermoplastic fuselage structures. Within the framework of TB-Rumpf, the welding process itself as well as the necessary welding elements are specifically optimized and the achievable mechanical values are validated.