Fraunhofer Institute for Casting, Composite and Processing Technology IGCV
Fraunhofer Institute for Casting, Composite and Processing Technology IGCV

OSFIT | One-Shot-Fully-Integrated-Thermoplastic-Frame

Efficient overall process chain for the production of integral, thermoplastic composite aircraft frames

Composite structures cannot yet compete with conventional metal structures in terms of manufacturing costs and cycle times. The aim of the project is to realize a cost-efficient process chain for composite aircraft frames with short cycle times.

The project OSFIT »One-Shot-Fully-Integrated-Thermoplastic-Frame« (FKZ: 20W1706D) comprises the development of an overall process chain suitable for series production for a composite aircraft frame with a thermoplastic matrix.

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Video OSFIT: One-Shot-Fully-Integrated-Thermoplastic-Frame

Thermoplastic Automated-Fiber-Placement (T-AFP)

The main competence of the Fraunhofer IGCV is the laying process, the thermoplastic Automated Fiber Placement, which is used to produce two-dimensional thermoplastic fabrics (preforms). The challenges here lie within the virtual generation of the laying deposit, the thermoplastic matrix material, and the stability and necessary cycle time of the overall process. The goal is the development of a reliable and yet highly automated laying technology, which is optimized with regard to the subsequent process chain.

Two-dimensional Thermoplastic Automated Fiber Placement (TAFP) Process at Fraunhofer IGCV
© Fraunhofer IGCV
Two-dimensional Thermoplastic Automated Fiber Placement (TAFP) Process at Fraunhofer IGCV
A detailed view into the »nippoint« during the TAFP process with laser activation
© Fraunhofer IGCV
A detailed view into the »nippoint« during the TAFP process with laser activation
Detailed view of the TAFP process in 90° orientation
© Fraunhofer IGCV
Detailed view of the TAFP process in 90° orientation

One-Shot Concept

The degree of consolidation of the preforms plays a decisive role here: the near-net-shape 2D preform is transferred to the final geometry by press forming after it has been deposited. The joining of stiffening and connecting elements is to be integrated into the pressing process, thus eliminating subsequent joining steps. At the end of the process chain is the assembly. Component-specific tolerances are compensated by means of automated geometry acquisition and additive manufacturing processes.

concepts for industrialization

This highly automated overall process chain, from tape material to assembly in the aircraft, is designed to save production time and costs by optimizing and coordinating the individual processes and the integral design of the frame.

Competences

We are shaping the way into the future of efficient engineering, networked production and intelligent multi-material solutions.

Competences

Industry solutions

The key sectors of Fraunhofer IGCV:

  • Mechanical and plant engineering
  • Aerospace
  • Automotive and commercial vehicles
Industry solutions

Cooperation with Fraunhofer IGCV

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Cooperation