ADVANCED MANUFACTURING OF MULTIFUNCTIONAL AEROSTRUCTURES FOR ZERO-EMISSION AIRCRAFT
The DOZE project aims to investigate new manufacturing concepts for lightweight, multi-material (combining thermoplastic composites with thermosets) and multi-functional (thermal management) aerostructures through highly sustainable out-of-autoclave processes. This will involve the development of functional composite materials, the optimisation of manufacturing processes and multi-material integration and the use of simulation tools for the optimisation of the design of functional and multi-material structures. Validation will be carried out on a demonstrator based on an aircraft electric motor fairing, with key requirements in terms of lightweighting and thermal management. Specifically, the DOZE solution will contribute to the design of these new aerostructure concepts through 3 main lines of research:
- Advanced Functional Composites Research
The project proposes to create new composite-based materials with superior thermal properties while reducing the weight of aerostructures by using thermoplastic and thermoset materials functionalised with additives with high thermal conductivity (mainly graphene and derivatives). Graphene, known for its exceptional conductivity and strength, will improve the overall performance of these composites, making them ideal for use in aerostructures with thermal management capabilities.
- Manufacture of Innovative Multimaterial Structures
DOZE proposes the combination of 3D printed thermoplastic parts with thermosetting resin transfer moulding (RTM) processes to create complex multi-material aerostructures. 3D printing will enable the production of complex designs with minimal material waste, while the subsequent RTM process will facilitate the bonding between TS-TP materials in a one-shot co-curing process, avoiding the need for subsequent joining/assembly processes. In addition, the application of thermal pastes to improve heat transfer in metal-composite bonds will be investigated, thus improving the efficiency and sustainability of the production of multi-material aerostructures.
- Simulation Tools for Design Optimisation
Advanced simulation tools will be used to support the design and optimisation of new materials and multi-material structures. These tools will facilitate the understanding of the functional behaviour of materials (especially multi-material joints) and allow prediction of their performance under various conditions. By integrating simulation into the design process, the project aims to optimise the properties of materials and multi-material structures, ensuring that they meet the stringent performance requirements of the aerospace industry.
The DOZE developments will be validated in a ‘DOZE demonstrator’ case study, based on a scaled-up section of an electric motor fairing consisting of a lightweight, thermally manageable multi-material (thermoplastic - thermoset) composite structure.