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Herone, Spiral RTC, Teijin Carbon Europe and Collins Aerospace Almere recycle A350 thermoplastic composite clips/cleats waste into rods for the all-thermoplastic composite Multifunctional Fuselage Demonstrator’s crown.

Fraunhofer IFAM and partners have completed left and right welds connecting the upper and lower fuselage halves and sent the 8×4-meter full-scale section to ZAL for integration with a cabin crown module and testing.

Thermoplastic composite upper and lower half shells for the Multifunctional Fuselage Demonstrator were welded using CO² laser over a total length of 8 meters.

Demonstrator’s upper, lower shells and assembly prove materials and new processes for lighter, cheaper and more sustainable high-rate future aircraft.

Eight-meter-long CFRTP fuselage skin was achieved via laser-heated in-situ consolidation, with stringers, frames and cleats to be welded.

Clean Sky project has delivered the 8 × 4 meter welded aerostructure component, aided by advanced thermoplastic composite technologies and smart robotics.

GKN Fokker and Mikrosam develop AFP for the Multifunctional Fuselage Demonstrator’s floor beams and OOA consolidation of 6-meter spars for TPC rudders, elevators and tails.

New developments in automated or semi-automated manufacturing solutions through MFFD, CoMMaNds 2, FastFlexMont 2, Tempo and UniFix projects to achieve sustainable, efficient composite part production.

Keynotes for the International Conference and Exhibition on Thermoplastic Composites on Oct. 9-10, 2024 include Randall Wilkerson’s update on the Hi-Rate Composite Aircraft Manufacturing project as well as Toray’s progress toward large-scale adoption.

Clean Sky 2’s MFFD program continues to move toward its goal of delivering a welded, thermoplastic composite fuselage demonstrator using next-generation manufacturing processes.