LuFo VI-3 NATURE | Sustainable helicopter structure

In order to realize the savings holistically and along the entire life cycle, the production processes are also ecologically evaluated in addition to innovative, recycled and bio-based materials.

The assessment includes the substitution of new fossil fibers and matrix systems with recycled or bio-based carbon fibers and bio-based matrix systems. The environmental impact is to be optimized using an automated »Design To Sustainability« methodology.

With the new consideration of the life cycle over the manufacturing and use phase, the CO2 footprint of the structural component is to be reduced by 25%. By considering opposing effects, the CO2 savings are secured so that a contribution is made to the goal of environmentally friendly aviation. The energy consumption in the production of a shell component is to be reduced by 50% compared to conventional prepreg autoclave construction, which will significantly increase the efficiency of production in terms of energy requirements and costs.

Currently, bio-based or recycled structural materials are hardly used in aviation for various reasons. In order to counteract this, NATURE aims to develop a basis for this and demonstrate the feasibility of components with at least 40% sustainable materials by mass.

In addition to CO2 savings, contributions are made to the decarbonization of aviation and technologies are developed that enable more eco-efficient products for the current and future helicopter market.

An innovative and newly developed design methodology for monolithic fiber composite structures should allow stable buckling in regular operation. This design of shell components promises potential weight reductions of up to 30%. This has a direct impact on energy consumption in flight and, together with the reduced use of materials, makes a further contribution to the goal of environmentally friendly aviation.

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• Identification, characterization and selection of sustainable lightweight materials (thin plies, rCF, bio-based C-fibers and matrix systems)
• Adaptation and development of production process chains for helicopter components made from new materials
• Technology integration of energy-saving production technologies
• Proof of positive climate impact through life cycle assessment methods
• Development, maturation and application of innovative design methods: Supercritical design and design to sustainability
• Identification of the permissible load level for the supercritical design of thin-ply structures
• Design of a structural assembly with the lowest possible CO2 footprint over the manufacturing and utilization phase
• Production and verification of the assembly with new/sustainable materials and technologies
• Demonstration and flight testing of the target components on a technology carrier