Manufacturing processes for thermoplastic composite structures

The FUTURE project’s main objective is the development of flexible manufacturing and welding processes for aerospace components made of thermoplastic matrix composites with variable thicknesses. These processes will enhance industrial competitiveness, optimize material usage, reduce production time and costs, and enable the fabrication of lighter, more efficient, and sustainable aerostructures, contributing to the decarbonization of the aerospace sector and the development of new vehicles such as UAVs and eVTOLs.

Expected outcomes include: i) advanced strategies for automated cutting and positioning of laminates, ii) 2D and 3D thermoforming processes using flexible and sensorized molds, iii) embedded sensor systems for real-time monitoring and quality control, and iv) continuous ultrasonic welding technologies with flexible welding heads to assemble complex geometries and dissimilar thicknesses. These innovations aim to increase the efficiency, reliability, and scalability of thermoplastic composite manufacturing processes in aerospace.

AIMEN plays a key role as a reference technological center, contributing its expertise in materials, advanced manufacturing processes, and monitoring, strengthening the capability of the Spanish industry to develop and implement high-value proprietary technologies for the production of next-generation thermoplastic aerostructures.