Automated and highly flexible thermoplastic composite structures manufacturing processes for zero-emission sustainable aviation
IGESTEK is participating in the FUTURE project in consortium with Aernnova and eProject4, supported by CDTI’s “Misiones Ciencia e Innovación 2024” program, within the “Sustainability and efficiency in air transport” area. The project has a duration of 16 months, ending in December 2025, with a total budget of nearly €2M and a non-refundable grant of €1M. Research organizations involved include Fundación CIDETEC and AIMEN (Asociación de Investigación Metalúrgica del Noroeste).
The main goal of FUTURE is to research thermoplastic composite manufacturing processes that enable more sustainable, flexible, and automated production of aerostructures required for new aircraft models such as UAVs and eVTOLs, as well as new single-aisle aircraft models, which will demand high production rates. The project focuses on the entire manufacturing line, from the lamination and layer positioning process to 2D laminate consolidation, 3D forming, and the joining of elements through welding. All proposed studies and research will be scaled into a representative demonstrator that will validate the feasibility of the production process for thermoplastic composite parts with variable thickness from a sustainable perspective, both in manufacturing and in the final product itself, promoting a circular economy.
IGESTEK’s activity in the project focuses on the research and development of processes for consolidating 2D laminates and forming 3D parts with variable thickness, as well as their specific tooling. For this purpose, it has an approximate budget allocation of €400,000. This is a strategic project for the company, whose research goals in FUTURE include the development of highly configurable tooling for the manufacturing of thermoplastic laminates, including complex geometries, variable thicknesses, and the integration of ad-hoc sensors. The aim is to optimize efficiency, sustainability, and quality in production.
Through this project, IGESTEK seeks to gain knowledge to develop more flexible tools and processes that enable zero-defect manufacturing of thermoplastic composites with highly complex geometries, ensuring high standards of quality and efficiency. These initiatives will not only improve the company’s current capabilities but also strengthen its position in the advanced composites market, particularly in the aeronautical sector, where weight reduction and improved manufacturing process efficiency are of utmost importance.
