The Fraunhofer Institute for Material and Beam Technology IWS has achieved significant progress in eco-friendly aircraft construction through their EU Clean Sky 2 project, “Multifunctional Fuselage Demonstrator” (MFFD). They have successfully demonstrated the chipless joining of carbon fiber-reinforced thermoplastic (CFRTP) components using the CONTIjoin process. This method, combining CO2 laser technology with dynamic beam shaping, enables the welding of large CFRTP fuselage sections without the need for autoclaves, leading to substantial reductions in weight, material use, and production time.
The process, which uses CO2 laser systems to weld long seams, enhances efficiency and reduces the need for mechanical fasteners. The project’s results show that this technology not only saves on labor and resources but also contributes to a lighter and more sustainable aircraft design. The new facility in Dresden produced a full-scale fuselage segment, demonstrating the feasibility and benefits of this approach.
The CONTIjoin process’s success in welding CFRTP components signifies a major advancement in aircraft manufacturing, potentially lowering fuel consumption and emissions. The technology will be showcased at the International Aerospace Exhibition ILA 2024 in Berlin. Future developments will focus on increasing the Technology Readiness Level (TRL) and exploring applications in other industries such as shipbuilding and rail transport.
The Fraunhofer Institute for Material and Beam Technology IWS has made notable strides in sustainable aircraft construction with their EU Clean Sky 2 project, “Multifunctional Fuselage Demonstrator” (MFFD). Their CONTIjoin process, which utilizes CO2 laser technology and dynamic beam shaping, allows for the chipless welding of carbon fiber-reinforced thermoplastic (CFRTP) components. This innovation eliminates the need for autoclaves, reducing weight, material use, and production time. The successful production of a full-scale fuselage segment in Dresden underscores the technology’s potential to enhance efficiency and sustainability in aircraft manufacturing. CONTIjoin will be featured at ILA 2024, with future developments targeting broader industrial applications.
