Process Simulation and Tool Compensation Methodology for High Temperature Composite Processes. The overall objective of ProTHiC is to develop materials, manufacturing, tooling and processing simulations technologies that enables further exploitation of carbon fibre-reinforced composites in applications where the temperature requirements are exceeding 200°C where currently only titanium or super-alloys are being used. ProTHiC will place its main efforts to: - Develop and characterize polyimide resins tailored for processing with RTM - develop, adapt and when necessary modify state-of-the-art processing simulation methodologies (curing and mould filling) to also work for high temperature composites - Validate simulation methodologies by against experimental data obtained from manufacturing trials performed on sub-components with simplified geometry (e.g. L- and T-profiles) - Establish a simulation assisted tool design process that integrates processing simulation methodologies with methodologies for tool compensation - Demonstrate the above-mentioned technologies by manufacturing of a demonstrator component that is defined together with the topic manager.

COMBO3D proposes to additively manufacture a short fibre reinforced thermoplastic tool with integrated active temperature control, to shorten the cure cycle time and so to focus on the objectives addressing the limitations and implementing the improvements of the state of the art project. By using a robot guided large scale short fibre reinforced plastics extrusion additive manufacturing process the tool can be produced as a single part, directly integrating the temperature control, shortening the lead-time and enabling simple and fast restoration of the tool surface to compensate for the expected lower lifespan. Using a robot-guided process also allows to print the final demonstrator tool in one piece in curved layers (real 3D printing). To ensure tool stability during the curing cycle, short carbon fibre reinforced semi-crystalline high performance thermoplastic PAEK will be used. Commercially available PAEK have a form stability of over 250°C in unreinforced grades and CF filled grades are available with heat deflection temperatures of 315°C and more. By introducing heating elements in the tool, it can conduct heat to the parts lower surface, in combination with the autoclave or oven, heating it up from both sides. These heating elements can be electrical or fluid channels connected to an external temperature control. Electric heating elements provide higher heat up rates but fluid heating allows to change from heating to cooling mode and hence to also cool the tool. Thereby it is possible to also achieve faster cool down. COMBO3D therefore proposes to use both heating elements in the tool. The whole development of the printed tool is supported by simulation. The design of the tool will be optimized by implementing the heating and cooling system in a thermal simulation. The manufacturing process simulation supports the printing process by generating knowledge about the temperature distribution during printing and correlating it with path planning.

This project aims to develop our innovative mould for efficient high-volume production of thermoplastic fuselage skin. Within the work of this project, first a process and mould will be developed for in autoclave consolidation, including automated layup, assembly, and transport. Second a mould usable for out of autoclave consolidation e.g. in situ consolidation with enhanced functionality for heating and cooling will be developed. Consolidation of thermoplastics at process temperatures of 400°C new challenges, such as large thermal expansion, temperature stability of sealings and cables. However, it offers opportunities to reduce significantly the cycle time and energy consumption, thereby improving the competitiveness. To overcome these challenges the consortium proposes to manufacture two moulds, one for in autoclave consolidation with limited functionality due to the high environment temperature and an enhanced mould for out of autoclave consolidation. A new temperature profile for the consolidation process is also proposed to be developed. For out of autoclave consolidation adequate surface structures will be investigated.

HAIRMATE project aims to design and manufacture moulds for manufacturing and testing the next generation aircraft seating obtained in the HAIRD project. Within the HAIRD project a new seating with reduction of Deep Vein Thrombosis (DVT) risk, multi-functionality and simple surfaces for composite manufacturing was designed. The moulds to manufacture the structural parts and the cushion will be manufactured. These moulds will be designed in detail taking into account the composite manufacturing techniques of Sheet Moulding Compound (SMC), Wet Compression Moulding (WCM) and Prepreg Compression Moulding (PCM) comoulded with SMC. If it is needed, the HAIRD seating design will be slightly redesigned to fulfil all the requirements of the moulds. A Life Cycle Assessment (LCA) data collection of materials and processes will be carried out. These data will be used to do an assessment of seating life-cycle to guarantee the new design and manufacturing improvements in terms of sustainability. Moreover, different tests will be performed to define the mechanical and fire safety properties of the materials developed by the Topic Manager (TM) for the manufacturing of the seating. Finally, a full-scale seating will be tested to analyse the structural reliability and to approximate the HAIRD seating design to the industry and thus to the market. Once again, some design and structural calculus loops will be carried out to improve the seating.