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Brandt, Lars
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Publications (7/7 displayed)
- 2023Thermocouple based process optimization for laser assisted automated fiber placement of CF/LM-PAEKcitations
- 2023Integral quality assurance method for a CFRP aircraft fuselage skin: Gap and overlap measurement for thermoplastic AFPcitations
- 2022Upscaling of in-situ Automated Fiber Placement with LM-PAEK - From Panel to Fuselage
- 2022How to Produce a Thermoplastic Fuselage
- 2019COMPARISON OF HEAT SOURCES FOR AUTOMATED DRY FIBRE PLACEMENT: XENON FLASHLAMP VS. INFRARED HEATING
- 2017Robot-based implant resistance welding of carbon fiber reinforced thermoplastics
- 2017Automated layup of spherical GLARE components using cooperating robots
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document
How to Produce a Thermoplastic Fuselage
Abstract
The CleanSky II Multifunctional Fuselage Demonstrator (MFFD) is the world's largest known aviation structure made of thermoplastic composites. The Center for Lightweight Production Technology (ZLP) in Augsburg together with Premium AEROTEC, supported by Aernnova and Airbus are responsible for the delivery of the 8m long upper half shell. The process chain of this crown shell is based on in-situ automated fiber placement for the skin placement, continuous ultrasonic welding of the stringers and resistance welding of frames and cleats. All of these production technologies represent major opportunities, however, associated with a multitude of corresponding risks. The main aspects of the development were thus driven by risk mitigation. Intense process development on coupon level was performed prior to verification of the respective technology bricks on a fullscale test shell with single aisle dimensions, and followed up by detailed root cause failure analysis. Thus, successful validation of design principles for a thermoplastic fuselage, its lean manufacturing and dustless joining technologies were achieved.