Advanced welding process for the manufacturing of thermoplastic composite aerostructure

The SAAT project’s main objective is the development of advanced ultrasonic welding (UT) technologies applied to high-performance thermoplastic composites (TPCs), aiming to enable the fabrication of large, lighter, more efficient, and sustainable aerostructures. This contributes decisively to aircraft weight reduction, supporting decarbonization and the integration of new sustainable propulsion systems, such as electrification or hydrogen use.

Expected outcomes include: i) new digital design and multiphysics simulation tools, ii) flexible welding equipment with real-time monitoring and control, iii) integrated in-line non-destructive testing systems, and iv) data-driven decision support methodologies to optimize welding processes. Together, these advances will increase the reliability, efficiency, and industrial scalability of UT welding for complex TPC structural components.

AIMEN plays a key role as a reference technological partner in the development of ultrasonic welding for composites. Building on its leadership in previous European projects and its participation in the MultiFunctional Fuselage Demonstrator (MFFD), AIMEN provides expertise in materials, advanced manufacturing processes, and monitoring, strengthening the position of the national and European industry in the next generation of zero-emission aircraft.