2022 - 2026

ZEUS - Zero Emission aircraft with sustainable fuselage concept and technology

Zero Emission aircraft with sustainable fuselage concept and technology

Thermoplastic, fibre-reinforced semi-finished products offer many advantages for primary structural components, especially in the fuselage area. In addition to their lower weight compared to metallic structures, they open up new possibilities in further processing, such as welding processes, as well as in recycling and the circular economy. Promoting their use in aviation requires reliable manufacturing processes and active research and development activities that take into account both material and technological properties and ensure economically viable productivity.

In its main work package 3, the German Aerospace Centre (DLR) is pursuing the goal of expanding expertise at material, technology and process level. Work is being carried out on a complex, double-curved fuselage skin in order to improve both component and process performance. Evaluation criteria in the preforming and consolidation areas are being determined and processes for rapid single component production are being derived and demonstrated. Using virtual manufacturing methods, this progress is to be transferred to target components on a real scale. In addition, the oven consolidation of flat laminates is being further developed as a cost-effective alternative to the autoclave process in order to establish thermoplastic technology.

DLR is also working on the structural realisation of large cut-outs for doors in aircraft fuselages. A special surrounding structure is being developed to transfer static and dynamic loads around the open cut-out. This includes the development of non-rectangular welding elements as well as methods for joining the door surrounding structure to the skin, in particular taking into account tolerance compensation and gap compensation during the joining process. Various approaches such as 3D measurement and the application of matrix material are being investigated to overcome these challenges.

Thermoplastic production in an autoclave - Part 1
Thermoplastic production in an autoclave - Part 2

DLR institutes & facilities involved

Institute of Structures and Design

High-performance lightweight structures for aerospace, vehicle construction and energy technology are the focus of research at the Institute of Structures and Design.

Project partners involved

Airbus Operations

Airbus Aerostructures

Albany - CirComp

Fraunhofer Gesellschaft

IVW

Xelis

Funding

Contact

Hakan Ucan

Project Manager
German Aerospace Center e.V. (DLR)
Institute of Lightweight Systems
Department Production Technologies
Ottenbecker Damm 12, 21684 Stade
Germany