The newly developed structural component with a complex rib structure was specifically designed for eVTOL aircraft, such as air taxis. KraussMaffei’s FiberForm process is used in its production. The result: manufacturing time is reduced from over 100 h to just 2 min compared to the metal variant while maintaining the same strength and safety.

The FiberForm process involves placing an organo-sheet – thermoplastic impregnated continuous fibres – into the mould, forming it and overmoulding it. Compared to conventional metal part manufacturing, this fully automated combination of thermoforming and thermoplastic overmoulding offers significant advantages, including lower costs, reduced weight and a fraction of the production time – all while ensuring the same mechanical strength and safety. At the same time, the FiberForm process allows for significantly greater design freedom.

3,000 times faster production compared to metal

The advantages of shorter cycle times become particularly evident with the newly developed rib structure. Traditionally, components of this kind are milled from a solid metal block – a process that removes more than 80% of the material and requires over 100 h of processing time . “In contrast, the thermoplastic component was formed and overmoulded from a flat organo-sheet in less than 2 min. The outstanding expertise of the partners involved was crucial to this success,”  explains Dr Waruna Seneviratne, director of Niar Atlas.

In addition to KraussMaffei, the companies Joby Aviation, Toyota, Victrex and Prospect were also involved in the development. The project is part of the Manufacturing for Affordable Sustainable Composites Program by the Air Force Research Laboratory.

Benefitting from automotive mass production

“The results highlight the potential of FiberForm technology, which originates from the automotive industry, for the mass production of primary and secondary structures in aerospace,”  Seneviratne continues. Eugen Schubert, sales and applications manager, IMM & automation at KraussMaffei, emphasises the importance of the Niar Atlas laboratory as an innovation platform:  “The Niar Atlas Institute provides an ideal environment where machine manufacturers, material suppliers and tooling developers can collaborate with aircraft manufacturers to test new materials and processes for demanding aerospace applications and develop them for series production.”

Continuing the success story of “preighter”

Niar Atlas and KraussMaffei have previously worked together in 2024. Back then, the focus was on FiberForm-manufactured window plugs used in the conversion of passenger aircraft into freighters, known as “preighter”. The window plugs were produced in just 90 s, were 20-30% lighter and cost half as much as their metal counterparts.

With the new complex rib structure, the development partners are now demonstrating FiberForm technology on a demanding structural component, paving the way for further applications and successful certification in the aerospace industry.