Fuselage Component Stiffening Profiles Additive Manufacturing
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Solution Overview
Problem
Current methods for manufacturing aircraft fuselage components using fibre composite materials lack efficiency and do not adequately enhance mechanical strength, particularly in the formation of intersecting stiffening structures.
Innovation Solution
A method involving the additive manufacturing of intersecting stiffening profiles using filaments with fibre bundles embedded in a thermoplastic matrix material, applied in a thermoplastic state to form continuous stabilising layers beyond intersections, creating a cohesive material connection and improving mechanical rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If strip elements are laid in grooves with crossing pieces at intersections, then the stiffening structure can be formed, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The stiffening profiles are segmented into discrete layers that are built up sequentially. Each layer contains filaments that are positioned and cured independently, allowing complex three-dimensional profiles to be constructed from simpler two-dimensional layers, thereby simplifying the manufacturing process while maintaining structural integrity
Solution Approach 2:
The manufacturing process transitions from laying strip elements in a single plane to building up layers in the thickness direction. This dimensional transition allows crossing pieces to be formed as integral parts of subsequent layers rather than being inserted separately, reducing manufacturing complexity
2Strength
If crossing pieces are inserted at groove intersections to connect strip elements, then the stiffening structure achieves mechanical strength, but the manufacturing time increases
Solution Approach 1:
The crossing pieces are merged with the stiffening profile structure itself. Instead of being separate inserted components, crossing pieces are formed as integral parts of the layered structure, where subsequent layers naturally incorporate the crossing functionality, thereby eliminating separate insertion steps and improving manufacturing efficiency
Solution Approach 2:
The positions of crossing pieces are predetermined and prepared in advance during the layer-by-layer construction process. Filaments in subsequent layers are positioned to form crossing pieces at required intersection points before final curing, allowing for optimized material placement and reduced manufacturing time
3Stability of the object's composition
If stabilising layers are formed with continuous fibre bundles extending beyond intersections, then the mechanical rigidity is enhanced, but the manufacturing precision requirements increase
Solution Approach 1:
The stabilising layers are segmented into discrete filament placements within each layer. By constructing the structure layer-by-layer with controlled filament positioning, the continuous fibre bundles are achieved through systematic repetition of precise discrete actions, making the precision requirements more manageable
Solution Approach 2:
The manual or mechanical placement of filaments is replaced with an automated fibre placement (AFP) system. This automated system uses computer-controlled mechanisms to deposit filaments with high precision and repeatability, ensuring continuous fibre bundles extend correctly beyond intersections while reducing the practical difficulty of achieving required precision
4Productivity
If intersecting stiffening profiles are built up layer by layer from filaments, then the manufacturing time is reduced, but the complexity of forming cohesive material connections increases
Solution Approach 1:
The material state parameter is changed during the manufacturing process. Filaments are applied in a thermoplastic state that allows for deformation and bonding, then cured to achieve final structural integrity. This parameter change enables cohesive material connections between layers and profiles during the accelerated layer-by-layer construction process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the mechanical strength and rigidity of fuselage components by forming continuous fibre bundles within stabilising layers, reducing manufacturing time and effort while allowing for complex cross-sectional shapes, such as T-shaped or Ω-shaped profiles.
Implementation Method 1
which each comprise a fibre bundle embedded in a thermoplastic material
Data Source
AI summary
A method for manufacturing a fuselage component for an aircraft includes building up, on a surface of a two-dimensional shell part composed of a fibre composite material, stiffening profiles crossing at an intersection from a plurality of layers, superimposed on one another in a thickness direction, which are each formed by applying filaments, which each comprise a fibre bundle embedded in a thermoplastic material. Stabilising layers, within which the filaments extend beyond the intersection, are formed from the filaments in each of the stiffening profiles. A fuselage component and an aircraft, which comprises at least one such fuselage component, are furthermore described.