Revolution in Aviation: Production of the Multifunctional Fuselage Demonstrator (MFFD)
Video Overview & Insights
We proudly present the summary from the manufacturing and assembly processes of the all-thermoplastic #MFFD upper shell.
Good day. I'm considering two airplanes, one for two and one for four people. Maximum speed 250 mph, cruising speed 210 mph. How can I find them? Where can I have them made? Please provide information. Thank you.
The Upper-Shell was built together with our dear partners Aernnova, Premium Aerotec and Airbus.
We would like to thank everyone involved, without whose continuous motivation, inspiration and team spirit this success would not have been possible.
What about safety, as the materials are highly toxic any fire incident happens, nobody will be saved because of toxic smoke, uncontrollable fire.
These are the key facts of the demonstrator:
- In-Situ consolidated lay-up of the skin (53 km tape placed in total)
Is Spirt still in Belfast?
- Production of 44 compression molded Z-stringers by Aernnova
- Robot-based ultrasonic spot welding of stringers for pre-fixation, each 500 mm
It looks neat BUT, you create a lot of interfaces that need fasteners and are weak points. Why not whole shape single piece layups, no interfaces anywhere and no stringers and frames because of double curvature shaping where carbon fiber is naturally rigid as just a shell? the so called teardrop shape. Hard to beat for weight. Difficult to make so thin that it can't hold 30 bar pressure.
And why not skip all the windows and use individual displays. That way they can look in every direction, everyone has a view and the hull cannot fail. Windows aren't an acoustic entry point either.
- World`s first fully automated, robot-based continuous ultrasonic welding of 44 stringers
- Production of 24 compression molded C-frames and loose parts by Premium Aerotec
The lander of Comet Philae was a success!
- Automated integration of 24 frames by resistance welding (~300 welds)
- Automated integration of 12 frame-couplings by resistance welding
Nice project, but the background music is just awful.
- Automated integration of ~158 cleats by cobot-based resistance welding (~316 welds)
Partner:
The first planes were made of carbon(wood) and fabric and glue... now they are trying to sell this as new innovative.
https://www.aernnova.com/
https://www.premium-aerotec.com/
Former Boeing Everett where 787 is made. We use huge rotating mandrels with AFP and ATL robotic heads robotically layers of carbon-fiber epoxy resin prepreg to contoured surfaces. Reinforcing fibers are oriented in specific directions to deliver maximum strength along maximum load paths. This produces and accurate copy of inside of fuselage. Demonstrator here actually makes a more dimensional accurate product. Using an inside mold produces exact dimensions of outside surface, which is very important.
https://www.airbus.com/
The Multifunctional Fuselage Demonstrator (MFFD) was developed as part of the Large Passenger Aircraft project and funded by the European Clean Sky-2 program.
Congratulations, what an awesome result of your project. I would love to see biangled layup based laminate though! Congrats again.
https://www.clean-aviation.eu/clean-sky-2/key-demonstrators/multi-functional-fuselage-demonstrator
Funding:
Thats not for an airplane but for a petrol rocket with wings, while a airplane ( an aircrfat that can plan, sail and soar by their own) can be built with flexible fabric covering with hemp fabric and a frame of recycled wood, cardboard and metal sheet
And it would be 30-50% lighter compared to composite shell fabrication
This project has received funding from the Clean Aviation Joint Undertaking (CAJU) under grant agreement CS2-LPA-GAM-2020-2023-01. The JU receives support from the European Union’s Horizon 2020 research and innovation program.
More Information:
Do you also made this available for commercial?
https://www.dlr.de/en/bt/research-transfer/projects/project-archive/mffd
its me or its overenginered? any test and comparation versus isogrid fuselage?
More User Perspectives
Looks amazing ... What is your matrix material and what are you using as a heater? Also are there any publications to read more in detail about this work?
@abdokorayem9478