DLR - German Aerospace Center
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As Seen On CompositesWorld
Editorial, News, and Products
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Developing milling for CMC because grinding takes too long
Economical processes that can cut machining time by 70% are being tested on aeroengine turbine blade demonstrators by Hufschmied and DLR in the SCANCUT project.
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DLR conducts aeroelastic vibration tests on Volocopter VoloCity
Analyzing structural resonance of the aircraft under various loads becomes a critical step in obtaining flight certification.
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Polaris Spaceplanes receives MIRA II, MIRA III fiberglass airframes
German aerospace startup prepares next demonstrators toward reusable space launch and hypersonic transport toward routine, low-cost and safe access to space.
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New CMC turbine vanes successfully tested in wind tunnel
SiC/SiC ceramic matrix composite (CMC) inlet guide vanes for a high-pressure turbine are aimed for a geared turbofan and show promise for more efficient aeroengines with less weight and need for cooling.
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MFFD longitudinal seams welded, world's largest CFRTP fuselage successfully completed
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.
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JEC World 2024 highlights: Thermoplastic composites, CMC and novel processes
CW senior technical editor Ginger Gardiner discusses some of the developments and demonstrators shown at the industry’s largest composites exhibition and conference.
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Broetje-Automation demonstrates rCF placement via AFP
Through the ScrapSeRO project, the system integrator and machine builder successfully processed recycled composites, in addition to more traditional materials, via its highly flexible Staxx One system.
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Innovation Award finalists revealed for JEC World 2024
Returning to the international composites trade show are the Innovation Awards, representing up to 33 finalists in 11 categories that highlight composites innovation excellence and fruitful collaborations.
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Top 10 CompositesWorld news items of 2023
Explore 2023’s standout moments in the composites industry with CW's compilation of the top 10 news articles, determined by Google Analytics.
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H2Fly completes piloted flight of LH2-powered electric aircraft
Joby subsidiary’s composites-intensive HY4 demonstrator took off from Slovenia and saw safe and efficient operation throughout multiple flight tests.
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DLR develops safe, flexible workspaces for robot-assisted manual draping
The EU project Drapebot works on new ways of collaborating with industrial robots for manual CFRP preforming for large aircraft structural parts.
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New Clean Aviation projects to facilitate highly efficient aircraft by 2035
Clean Aviation, approved for €380 million to advance eight topics revolving around new aircraft concepts and propulsion architectures, reveals project focuses and partners.
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Manufacturing the MFFD thermoplastic composite fuselage
Demonstrator’s upper, lower shells and assembly prove materials and new processes for lighter, cheaper and more sustainable high-rate future aircraft.
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Aciturri joins r-LightBioCom project for bio-based HPC advancement
A catalog of novel, sustainable composites, including bio-resins, biomass-derived nanofillers and additives, fiber-based textiles and corresponding technologies, will be developed during this three-year EU project.
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Lilium receives capital raise, enters Lilium Jet for wind tunnel testing
Powered test campaign at the German-Dutch Wind Tunnels (DNW) facility in Marknesse, Netherlands, and up to $250 million in capital raise advance the eVTOL company toward its first type-conforming aircraft.
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Demonstrating functionalized, cost-effective composites using additive extrusion
Hybrid thermoset/thermoplastic composite part with 3D-printed functionalization demonstrates technology possibilities and EmpowerAX open platform offering expertise from members throughout the process chain.
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JEC Composites presents 2023 Innovation Award finalists
This year’s 30 Innovation Award finalists representing 11 categories portray excellence in composites innovation and fruitful collaboration.
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STUNNING project completes lower half of MFFD
Clean Sky project has delivered the 8 × 4 meter welded aerostructure component, aided by advanced thermoplastic composite technologies and smart robotics.
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Composites end markets: Aerospace (2023)
With COVID in the past and passengers flying again, commercial aircraft production is ramping up. The aerocomposites supply chain is busy developing new M&P for an approaching next-generation aircraft program.
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DLR, NLR extend cooperation in aerospace, sustainability
Building on a longstanding, 50-year partnership, both executive boards are stepping up their game regarding aeronautics, sustainability, climate-neutral aviation, uncrewed flight.
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DLR develops additive WeldSealer process to seal joints, edges or modify surfaces
The robotic process developed for large components protects joints and edges, prevents cracks and allows multipart structures to be created as if cast in one piece.
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CFRTP upper stage propellant tank
PROCOMP uses in-situ consolidation AFP and ultrasonic welding to demonstrate lightweight, novel tank design.
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Thermoplastic composites welding: Process control, certification, crack arresters and surface prep
More widespread use of welded composite structures within a decade? Yes, but further developments are needed.
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Thermoplastic composites welding advances for more sustainable airframes
Multiple demonstrators help various welding technologies approach TRL 6 in the quest for lighter weight, lower cost.
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Multi-flange RTM frames enable radical rear fuselage design
The Clean Sky 2 Advanced Rear End (ARE) demonstrator combines patented new frame design, thermoset and thermoplastic composites and smart tooling to advance aircraft design and cut weight, cost and production time.
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RATH prepares for production of advanced oxide ceramic fiber for CMC
New facility in Germany is part of regional supply chain and vision to lead green energy transition using CMC, supported by German government and Composites United’s Ceramic Composites network.
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DLR Augsburg integrates sixth frame to upper half fuselage test shell for MFFD
Clean Sky 2 thermoplastic composite demonstrator advances toward full assembly.
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DLR Institute of Structures and Design releases video on TB-Rumpf welded thermoplastic composites
Autoclave-free consolidation and resistance welding validated for future aircraft thermoplastic composite fuselage.
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University of Auckland, DLR researchers cooperate in space research
New Zealand and German space experts are partnering up for research into using carbon fiber for spacecraft and laser light technology to transmit data to Earth.
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Sensors for Composites Processing: CW Trending Episode 8
Why use sensors in composites manufacturing? What sensor types are available and how can they be applied? Learn about all of this and more in a discussion with CW senior editor Ginger Gardiner and editor-in-chief Jeff Sloan in this episode of CW Trending, sponsored by RVmagnetics.
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Sensors: Data for next-gen composites manufacturing
In the quest for sustainability, sensors are reducing cycle times, energy use and waste, automating closed-loop process control and increasing knowledge to open new possibilities for intelligent manufacturing and structures.
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Multi-composite thrust chamber aims to boost rockets, reduce cost for New Space economy
Black Engine uses new, microporous CMC liner for transpiration cooling and multiple lightweight composites in modular design that offers increased lifetime and lower maintenance versus current launch vehicle engines.
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Customizing ultrasonic sensors for composites process optimization and control
University of Augsburg developed sensors for the CosiMo project’s digital twin and closed-loop process control of EV battery box cover demonstrator, and now moves forward with the AI Production Network for industry collaboration.
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SAM|XL develops closed-loop manufacturing for composites
Collaborative R&D center at TU Delft develops sensor- and robot-based automation for Composites 4.0 manufacturing, including STUNNING project for welded assembly of a thermoplastic composite fuselage demonstrator.
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CosiMo: Smart thermoplastic RTM process demonstrated for battery box cover challenge simulator
Project uses network of DEA, temperature/pressure and ultrasonic sensors plus digital simulation and AI modeling to monitor and optimize injection of caprolactam into complex glass fiber preform and in-situ polymerization of PA6.
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DLR Institute of Structures and Design increases maturity of thermoplastic composite fuselage structures
Project with Airbus demonstrates OOA co-consolidated stringer-stiffened skin with resistance welded frame and cleats.
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Artificial intelligence optimizes CNC milling of carbon fiber-reinforced composites
The Augsburg AI Production Network — DLR Center for Lightweight Production Technology (ZLP), Fraunhofer IGCV and University of Augsburg — use ultrasonic sensors to correlate sound to quality in composites machining.
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Clean Sky 2 FRAMES project advances heating simulation of thermoplastic composite AFP with xenon flashlamp
Heraeus Noblelight and Compositadour develop heating simulation to optimize process temperatures during automated fiber placement of composite aerostructures.
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DLR develops concept for final assembly line with artificial intelligence
High-rate production enabled by pre-selection of assembly-ready components, without manual compensation measures, based on neural network training.
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Reducing the cost of continuous fiber 3D printing materials
DLR has developed a novel approach to produce thermoplastic impregnated fibers for lower cost versus current slit-tape materials.
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EmpowerAX strengthens accessibility to continuous fiber 3D printing
Platform joins technology users and providers to work on standards, tests and frameworks for faster, lower-cost evaluation and implementation of additive extrusion technologies for industrial parts.
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INVENT GmbH demonstrates sensor network for structural monitoring on composite railcar structures
Patented DuraAct technology uses piezo-ceramics to detect damage in Deutsche Bahn train side skirts as part of faWaSiS research project.
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DLR launches EmpowerAX to industrialize continuous fiber 3D printing
Global, industry-diversified platform will increase access to additive extrusion (AX) technologies and accelerate technology transfer for users and providers.
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Hydrogen fuel cell-powered HY4 aircraft takes flight
MAHEPA consortium demonstrates feasibility and advances toward liquid hydrogen tanks and scaling modular HY4 technology to new, emissions-free aircraft.
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Future composite manufacturing - AFP and Additive Manufacturing
TU Munich symposium explores how these technologies are merging and reviews R&D that is creating a path forward.
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Moving forward on the Multifunctional Fuselage Demonstrator (MFFD)
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.
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Using sensor data to improve composite parts and processes
nebumind software builds digital twins from manufacturing data to trace defects, compare manufactured parts, qualify processes, develop tolerance windows for process monitoring and more.
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FRAMES: Full-scale thermoplastic composite aircraft rear-end demonstrator
Clean Sky 2 project led by ESTIA-Compositadour will develop enabling technologies for optimum rear fuselage and empennage.
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Future Composite Manufacturing virtual symposium for AFP and AM
The virtual symposium, held Sept. 9-10, 2020, will focus on current state, trends and opportunities for automated fiber placement (AFP) and additive manufacturing (AM).
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Composites 4.0: Digital transformation, adaptive production, new paradigms
An evolving landscape of automation, sensors and AI software is not an end, but a means to achieve the cost, quality, efficiency and agility required for future manufacturing.
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Digital thread vs. digital twin
Visualizing the difference between digital representations and data flows and understanding the applications that are changing composites manufacturing and business models.
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No business case for reteaching robots
DLR Center for Lightweight Production Technology has developed an AI-equipped work cell where collaborative robots can switch from producing composite rear pressure bulkheads to fuselage panels without requiring reprogramming or retraining.
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Composites 4.0: Architecture and ontology
Adaptive systems, IoT platforms and apps, the need for 4.0 standardization and a new way to develop and certify composite aerostructures.
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Combination of automation, rigid foam core enable high-volume aircraft part production
A feasibility study demonstrates increased production capacity using Evonik foam core and automated manufacturing.
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DC dielectric sensors for industrial composites production
Synthesites in situ process monitoring enables cure decisions based on real-time Tg evaluation that can reduce cure cycles by up to 50%.
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Advancing thermoplastic composites and RTM for Clean Sky 2 in Spain
EURECAT leads projects for TPC keel beam, window frames and thermoset RTM fuselage frames with TPC shear ties for next-gen aircraft.
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Premium AEROTEC displays thermoplastic CFRP pressure bulkhead
Demonstrator at Paris Air Show advances resistance welding toward serial manufacturing of composite fuselage shells for next-generation aircraft.