Digitalization and Efficient Manufacturing Technologies

The fascination of mastering complexity

As part of the Aviation Research Programme (LuFo), the Digitised and Efficient Manufacturing Technologies department in the Aeronautics Research Programme (LF-DEF) is responsible for all research projects focusing on structures and construction methods as well as digitisation technologies.

In order to reduce the energy requirements of the aircraft, the department is focussing in particular on the following measures:

Weight reduction of all structures, new construction methods
New materials and construction methods

Another significant focus of the department is on increasing competitiveness and resource efficiency:

Reduction in production costs
Reduction of operating costs
Reduction of development times
Reduction of production system development times
Increase in the rate ramp-up speed
Closed material cycle processes

Reasons for the research

The central objective of LuFo is to significantly reduce the climate impact of aviation through aviation-induced greenhouse gases and non-CO2 effects. In order to meet the requirements and goals of the Paris Climate Agreement[1], the EU Commission's Green Deal[2] and the German government's Climate Protection Act[3] and to strengthen social acceptance, intensive efforts towards climate-neutral aviation and to further reduce the consumption of materials and resources in production are necessary in coordination with the EU funding programmes (Horizon Europe[4], Clean Aviation[5]) and other European nations. The expected increase in air traffic volume and the integration of new unmanned aerial vehicles into the airspace will only be possible in future with more efficient and climate-neutral air transport and production systems.

The focus of LuFo is based on three pillars:

alternative climate-neutral technologies,
reduction of energy requirements and
increasing competitiveness, resource efficiency, reducing the ecological footprint and improving social acceptance

The Digitalised and Efficient Manufacturing Technologies department in the Aeronautics Research Programme (LF-DEF) addresses the second and third pillars in particular.

The importance of these topics is evident in the opportunities, but also in the challenges. Optimisation of efficiency, weight, costs and climate compatibility are addressed in all areas.

Current research focus

The department's current research focuses, divided into the specialist areas of "Structures and Construction Methods" and "Digitalisation Technologies", can be summarised as follows:

Department of Structures and Building Methods:

Funding is available for topics relating to primary fuselage, wing, rotor and tail structures as well as secondary structures of commercial aircraft, general aviation aircraft, rotorcraft, UAM and UAS. The main topics are

Weight-reduced, functionally integrated structural concepts and construction methods to reduce energy requirements
Innovative, integrated simulation methods for accelerated development processes
Environmentally friendly manufacturing, assembly, MRO and end-of-life processes,
Energy and resource-efficient manufacturing processes, with entry into the circular economy and reduced waste
Ergonomic processes / technologies to support workers (design for ergonomics)
Development of LCA methods to assess sustainability over the entire product life cycle
Lighter, automated production equipment such as end effectors / cobots
- Windowless cell, blended wing concepts, new cell concepts
Bionic structures

Department of Digitalisation Technologies:

Funding is provided for topics relating to the development of digitalised aviation methods and processes that contribute to a significant increase in efficiency across the entire product life cycle. The main topics here are

Digital twins of the systems and the overall system for all phases of the product life cycle
Cost-efficient digitalised engineering, manufacturing, operational and end-of-life processes as a key enabler for climate-neutral aircraft
Digitalisation of the manufacturing system with simulation methods, digital process twins Industry IX
Combined virtual and physical testing methods for structural / system verification through to virtually supported approval
Data/AI-supported manufacturing system optimisation
More flexible, mobile manufacturing systems through to fully automated production lines (where appropriate)
Traceable AI methods
Automated flight controls
Quantum computing

Goals

The central goal is to significantly reduce the climate impact of aviation. This requires intensive efforts to achieve emission-free and climate-neutral aviation and to further reduce the consumption of materials and resources in production. The expected increase in air traffic volume and the integration of new unmanned aerial vehicles into the airspace will only be possible in future with more efficient, emission-free and climate-neutral air transport and production systems.

The primary goal for the area of digitalised and efficient production technologies is to reduce primary energy requirements and increase the competitiveness and resource efficiency of aircraft.

The following primary targets are being pursued in the medium term up to 2035:

40% reduction in weight
Reduction of energy requirements by 50
Reduction of production costs and times by 50%.

At the same time, the other goals of maintaining a high level of safety and reducing perceived noise by 50 % remain unchanged.

A lower energy requirement of the aircraft, in particular through weight reduction, has a direct effect on lower consumption of the propulsion systems, reduces residual emissions and compensates for the higher costs of future energy sources. The reduction in production costs and times also helps to compensate for the higher costs of future energy sources.

Another major potential for reducing the climate impact of air traffic is the reduction of non-CO2 effects - particularly through suitable long-haul and medium-haul flight routes. In order to demonstrate the commercial feasibility and effectiveness of climate-optimised flight routes in the coming years, political framework conditions and the introduction of technical innovations are required. This includes increasing automation and standardisation in aircraft, air traffic management and flight guidance.

Against this backdrop, the aviation research programme supports technological developments that make flying sustainable, climate-neutral and safe. Five time horizons in the priority aircraft classes serve as orientation markers. Short implementation horizons are made possible for unmanned aerial vehicles. This is followed by the CS-23 class by 2028, regional aircraft by 2030, medium-haul by 2035 and long-haul by 2045. The first technology modules must be validated with a lead time of three years from 2025. The technical solutions and concepts developed will make a significant contribution to sustainable air transport and thus strengthen the competitive position of Germany as an aviation centre.