JEC COMPOSITES MAGAZINE - Issue #135 - July/August 2020 - 34

FEATURE OOA
of including process variations tailored
to the needs of a particular industry.
However, this process requires a high
initial investment in moulds and tools,
involves high cavity filling times and,
depending on the variant, produces a
high void content, while the aeronautical sector accepts a maximum void
content of 2%.
OOA processes such as RTM and LRI
are not sufficiently mature yet, especially for the manufacture of primary
structures subjected to severe loads.
Collaborative projects
With extensive experience in manufacturing processes for lightweight
composite structures, the EURECAT
Technology Centre leads and participates in several Clean Sky 2 projects
to study the technical feasibility of
OOA processes in the development of
composite aerostructures, more specifically using RTM and thermoforming
technologies. Clean Sky 2 is the largest
European research programme for the
development of state-of-the-art technology to reduce the CO2 emissions
and noise levels of aircraft. Funded by
the EU's Horizon 2020 programme,
Clean Sky 2 contributes to strengthening European industrial partnerships
and competitiveness through calls for
specific activities agreed with main
OEMs and players.
EURECAT is highly transverse, working in the automotive, rail and other
industries in addition to its work in
aerospace for lightweight structural
components. It specialises in the development and advanced manufacturing
of composite materials (thermoplastics
and thermoset) applying circular
economy and sustainability principles.
Composites 4.0 is one of its strategic areas, applying digital twin technologies
and automation to improve manufacturing processes.
The centre's most recent Clean Sky 2
projects related to OOA manufacturing
processes for composite aerostructures
are:

- COFRARE 2020 (GAP no. 82126):
"Out of autoclave processes development for composite frames manufacturing with high production rate
and low cost", where EURECAT is
the project coordinator, DEMA and
ABETE are industrial partners, and
LEONARDO is the Topic Manager.
- WINFRAME 4.0 (GAP no. 821323):
"Full scale innovative composite
windows frames for Regional
Aircraft fuselage barrel on-ground
demonstrators", where EURECAT is
the project coordinator, SOFITEC
is an industrial partner, and
LEONARDO is the Topic Manager.
- KEELBEMAN (GAP no. 785435):
"Keel beam manufacturing oriented
solution", where EURECAT is the
project coordinator, SOFITEC, CT
Engineering Group and CETMA are
partners, and AIRBUS is the Topic
Manager.
- COFRARE 2.0 (GAP no. 717070):
"Out of autoclave processes development for composite frames
manufacturing with high production
rate and low cost", where DEMA is
the project coordinator, EURECAT
and APPLUS are partners and
LEONARDO is the Topic Manager.
These projects received funding from
the Clean Sky 2 Joint Undertaking
under the European Union's Horizon
research and innovation programme.
RTM manufacturing
of fuselage frames
The goal of the next-generation
COFRARE 2020 project is to manufacture full-scale composite frames and
shear ties for the Clean Sky 2 fuselage/
cabin integrated ground demonstrator.
This demonstrator is organized within
Clean Sky 2's Regional Aircraft IADP
(Innovative Aircraft Demonstrator
Platform).
The fabrication of composite fuselage
frames, shear ties and related splices
for regional aircraft will use advanced,
innovative industrial OOA composite
manufacturing processes that signifi-

jec composites magazine / N°135 July - August 2020

Fig. 2: Composite frame
manufacture by RTM technology

JEC COMPOSITES MAGAZINE - Issue #135 - July/August 2020

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