Innovative manufacturing techniques are revolutionizing how aerospace composites are made. From 3D printing to robots and beyond, the experts at Axiom Materials tell us that new technologies allow more efficient, consistent production of strong, lightweight composite components for aircraft and spacecraft. Let’s explore some breakthrough methods that promise to accelerate composites manufacturing.
3D Printing Reshapes Production
Also known as additive manufacturing, 3D printing builds up parts layer-by-layer rather than traditional machining, which cuts away material. On aircraft, 3D printed metal and plastic components make systems lighter to improve fuel efficiency. This includes intricate brackets and housings which are challenging to forge conventionally.
But now, 3D printing is also entering the world of structural aerospace composites. Researchers have developed enormous printers to fabricate large composite structures like wing spars and fuselage barrels straight from digital files. Benefits over conventional composite fabrication include:
- Speed – Printing directly net-shaped parts skips lengthy tooling setups for molds and dies. This slashes production schedules significantly.
- Design Freedom – Unconstrained by tooling restrictions, engineers can create radical new shapes optimized for strength and weight.
- Assembly Reduction – Consolidating assemblies into fewer printed parts simplifies manufacturing.
- Consistency – Printers apply each layer precisely for uniformity across entire production runs.
Automation Improves Quality and Rate
Laying up composite materials involves much manual labor as technicians hand-place successive plies of fibers into molds. But human inconsistencies can sneak in. Robotic systems now automate fabrication for improved repeatability.
Gantry-based devices follow programmed paths to position pre-cut fabric plies flawlessly onto tools. Robotic arms also excel at precise material placement while measuring applied force and angle in real-time to spot defects. Some systems even use AI vision to inspect each ply, catching flaws human inspectors could miss.
Substituting automation for manual tasks allows aerospace factories to achieve higher composite quality along with multiplying production volumes. The technology works around-the-clock without fatigue or slips in workmanship.
Microwave Production Speeds Curing
Traditionally, autoclaves slowly cook composite bonds using hot circulating air. Microwaves now accelerate this curing stage. Ovens packed with microwave generators direct focused energy deep into parts. The molecular vibrations evenly heat materials from within to rapidly solidify resins.
Compared to hour-long autoclave runs, microwave-assisted heating slashes curing durations to minutes. This radical reduction benefits high-volume manufacturing. Along with speeding rates, microwaves also yield composites with higher strength and thermal resistance.
Out-of-Autoclave Processing
Massive autoclaves pose limitations, as only one giant aircraft section can fit inside at a time. Out-of-autoclave (OOA) methods now let composites cure without these huge pressure vessels. OOA techniques often combine microwave with heating blankets and mold counterpressure.
Besides enabling bigger, more integrated structures, OOA drives down infrastructure costs versus autoclaves. Removing the pressure vessel improves visibility of the curing process, allowing for fine-tuned control and optimal properties.
Aerospace Composites: The Future is Now
Next-generation aircraft already exploit these breakthroughs for unparalleled performance goals. For example, NASA’s experimental X-57 electric plane incorporates 3D printed parts to achieve incredibly light yet stiff wing structures necessary for high efficiency.
Likewise, Airbus’ new A350XWB wide-body jet employs an innovative OOA cured carbon fiber fuselage, bringing step-change reductions in weight along with lower production costs.
In addition, Boeing’s in-development 777X model will sport the largest composite wing ever at over 234 feet long thanks to robotic manufacturing with extreme precision.
Conclusion
Additive printing, smart robots, microwave heating and out-of-autoclave curing represent new frontiers empowering aerospace composites manufacturing. Leveraging such technologies promises airframes with unprecedented dimensions and optimizations for the next generation of lighter, tougher, more capable aircraft that fly farther on less fuel. Fast-evolving production methods will thereby help aviation stay at the forefront of composites innovation.
