Daher confirms continuation of R&D efforts for thermoplastic composites

Thermoplastic composite materials are the key focus of Daher’s (Nantes, France) research and development (R&D) efforts to decarbonize aviation, further exemplified through the company’s development of various thermoplastic aerostructure components mobilized by numerous R&D programs. 

Daher has set ambitious objectives under its “Take off 2027” 5-year strategic plan, which commits to quadruple the company’s R&D project investments (read “Daher  launches open innovation program, accelerates aviation decarbonization commitment”). To meet the challenges of its customers, Daher is focusing on making aerostructures lighter and developing new materials that contribute to lowering overall aircraft weight, thereby reducing fuel consumption and CO₂ emissions.

The company says it is devoting significant efforts to pursuing aeronautical applications for thermoplastics in particular — focusing on the design, manufacture and assembly of such parts. To strengthen its capabilities for composites of the future, Daher launched the Shap’in innovation center near Nantes, France, in 2022, which is dedicated to advanced composite aerostructures. The center’s goal is to continue the aerostructures research carried out by Daher during the past 10 years, working in collaboration with the ecosystem of the EMC2 competitiveness cluster and the Jules Vernes technological research institute (Bouguenais, France).

Daher reports the development of numerous thermoplastics projects for use in wings, for ribs, with welding, and for the engine environment:

• In partnership with Airbus, Daher produced an air inlet frame for an engine demonstrator. This piece, with a circumference of several meters and made up of four assembled sections, is said to be one of the largest ever produced in thermoplastic material;
• EcoWingbox: A 14-meter-long composite wing project;
• Wing of Tomorrow: Daher is a partner for Airbus in this project, and is responsible for the design and manufacture of highly loaded thermoplastic ribs;
• TRAMPOLINE 2: Since 2020, Daher has been leading an ongoing French research project for thermoplastics (TheRmoplAstic coMPosite for hOrizontal tall plaNE). This project constitutes a new technological breakthrough, involving thermoplastic welding by induction (without riveting);
• Carac TP: This project confirms the performance of long fiber composites with a thermoplastics matrix in the aeronautics sector:
  • High level of resistance (to humidity and the effects of fuel);
  • Assembly by welding, therefore without the need for metallic parts and the associated gain in mass;
  • Saving energy and time during production, which makes it possible to accelerate production rates;
  • Recycling;
  • A reduced ecological impact, as a result of less material loss during production.

Read more about thermoplastic aerostructures, including updates to the MFFD, welded thermoplastic composite patch repair and advances in thermoplastic composites welding.