Cost reduction in manufacturing of aerospace composites

Abstract

Advanced fibre reinforced composites are already extensively used in modern aircraft, due to advantages offered for weight reduction, durability, mechanical performance, etc. However, composite structures in aerospace are usually not associated with low costs. Traditional design methods are very time consuming, materials and production processes very expensive as well as labour intensive. To make full use of the potential of composites, a complete redesign of aircraft structures is necessary. Owing to qualification and certification procedures the introduction of low cost materials or low cost production processes is hindered. The current paper describes the results of a collaborative research project aimed at achieving significant cost reductions in the manufacturing of advanced composites for aerospace applications. A highly integrated redesign of a generic wingbox section was made and a low cost, room temperature, open mould (non‐autoclave) resin infusion production process was developed using a room temperature curing resin system for the production of the demonstrator.