The National Institute for Aviation Research (NIAR) at 萝莉社has engineered an advanced thermoplastic rib structure, showcasing the potential of fully automated hybrid thermoforming and injection overmolding.
The program, led NIAR鈥檚 Advanced Technologies Lab for Aerospace Systems (ATLAS) cuts production time from 100 hours to two minutes, marking a major breakthrough in aerospace manufacturing efficiency. By integrating two key polymer processing techniques, the process enables the production of high-performance, lightweight components with greater design flexibility and cost efficiency.
The development was part of the Air Force Research Laboratory鈥檚 Manufacturing for Affordable Sustainable Composites program and was made possible through collaboration with industry leaders, including Joby Aviation, Toyota, KraussMaffei, Victrex, and Prospect.
鈥淭his was a particularly challenging component, traditionally machined from a metal
billet鈥攁 process
that removes over 80 percent of the material and takes more than 100 hours to complete,鈥�
said Dr. Waruna Seneviratne, director of NIAR ATLAS. 鈥淚n contrast, the thermoplastic
part was formed from a flat thermoplastic organosheet in under two minutes. The expertise
of each partner was instrumental in achieving this success.鈥�
Last year, NIAR researchers collaborated with KraussMaffei to develop a thermoplastic overmolded window cover for passenger-to-cargo conversions that can be produced in just 90 seconds. The resulting component was 20鈥�30 percent lighter and cost half as much as its metal counterpart.
鈥淭hese advancements underscore the potential of automotive-matured overmolding technology for high-rate production of both primary and secondary aircraft structures,鈥� said Seneviratne.
Eugen Schubert, an application engineer at KraussMaffei, emphasized the value of NIAR鈥檚 ATLAS facility in fostering innovation.
鈥淚t provides a collaborative environment where equipment manufacturers, material suppliers, and tool designers can partner with aircraft manufacturers to de-risk the introduction of new materials and processes in demanding aerospace applications,鈥� he said.
The project has also expanded its collaboration to include Fill Engineering, aiming to develop a fully integrated manufacturing cell for rib structure production. This advanced system will incorporate material preparation, tape-laying, ultrasonic tack welding, consolidation, organosheet trimming, and overmolding. The production cell is scheduled for commissioning at NIAR in the fall of 2025.
In addition, researchers have broadened their study to include thermal, physical, and mechanical testing to validate process repeatability and ensure part quality. These efforts will provide crucial certification guidance for overmolded aircraft structures.
鈥淣IAR鈥檚 work aligns with the aerospace industry鈥檚 ongoing shift toward sustainable, high-performance materials and advanced manufacturing techniques that improve efficiency while reducing costs,鈥� said Seneviratne. 鈥淎s high-rate production methods continue to gain traction, innovations like these could play a pivotal role in the future of aerospace manufacturing.鈥�