Automated Assembly of Thermoplastic Fuselage Structures for Future Aircrafts

Abstract

In order to meet the high demand for aircrafts and the strict requirements regarding CO2 emissions in the future, new designs and technologies are necessary. Existing aircraft layouts and production processes are not designed for production rates of more than 75 aircrafts per month. One promising approach to reach significant improvements regarding weight and process cycle time is the combination of thermoplastic carbon fiber reinforced plastic aircraft structural elements, lining parts and cabin system elements to one integrated structure module. By this, improvements in productivity and environmental sustainability are accomplished likewise. This paper provides an overview of the Clean Sky 2 Multifunctional Fuselage Demonstrator, which comprises these topics. The focus of the scientific discourse lies on the concept of the full-scale assembly demonstrator especially discussing handling technology for position and shape adjustment of fuselage shells. Moreover, a systematic evaluation of thermoplastic welding technologies and a discussion regarding welding joint design is presented.