- Renowned NIAR Institute relies on thermoplastic composites process for highly complex rib structures
- 3000 times faster production compared to metal
- More design freedom and better cost efficiency
KraussMaffei and the National Institute for Aviation Research (NIAR) at Wichita State University, USA, are setting new standards in thermoplastic lightweight construction for aviation. Together, they have developed an innovative structural component with a complex ribbed structure that has been specially designed for eVTOL aircraft – electrically powered aircraft that can take off and land vertically. The proven FiberForm process from KraussMaffei is used. The result: the production time is reduced from over 100 hours to just two minutes compared to the metal version – with the same strength and safety.
In the FiberForm process, a so-called organo sheet, thermoplastically impregnated continuous fibers, is inserted into the tool, formed and overmolded. Compared to the production of metal components, this fully automated combination of thermoforming and thermoplastic overmoulding offers significant advantages such as lower costs, less weight and a fraction of the time required. And all this with the same mechanical strength and safety. At the same time, the FiberForm process allows significantly more design freedom.
At the NIAR “Advanced Technologies Lab for Aerospace Systems” (ATLAS), this is done on a GXW 450-2000/1400 from KraussMaffei with a clamping force of 4500 kN and a turning unit as well as a suitable automation solution with two IR industrial robots.
3000 times faster production than with metal
The short cycle times compared to metal are particularly evident in the newly developed and tested ribbed structure. Traditionally, components of this type are milled from a solid metal block – a process that removes more than 80 percent of the material and takes over 100 working hours. “In contrast, the thermoplastic component was formed and overmolded from a flat organic sheet in less than two minutes. The proven expertise of the partners involved was crucial to this success,” explains Dr. Waruna Seneviratne, Director of NIAR ATLAS. In addition to KraussMaffei, the companies Joby Aviation, Toyota, Victrex and Prospect were involved in the development. The project is part of the Air Force Research Laboratory’s “Manufacturing for Affordable Sustainable Composites” program.
Benefiting from large-scale automotive production
“The results underline the potential of the FiberForm technology known from the automotive industry for the series production of primary and secondary structures in aviation,” continues Seneviratne. Eugen Schubert, Sales and Applications Manager, IMM & Automation at KraussMaffei, emphasizes the importance of the NIAR ATLAS laboratory as an innovation platform: “The NIAR ATLAS Institute offers an ideal environment in which machine manufacturers, material suppliers and tool developers can work together with aircraft manufacturers to test new materials and processes for demanding aerospace applications without risk and develop them for series production.”
Continuation of the successful “Prachter” product
NIAR ATLAS and KraussMaffei already worked together successfully in 2024. At that time, they were working on window fasteners manufactured using the FiberForm process, which were used for the conversion of passenger to cargo aircraft, known as “prachters”. The window fasteners were produced in just 90 seconds and were 20 to 30 percent lighter and only half the price of their metal counterparts.
With the new, complex rib structure, the development partners are now demonstrating FiberForm technology on a sophisticated structural component, paving the way for further applications and successful certification in aviation.
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