Design for Manufacturing of Composite Structures for Commercial Aircraft – The Development of a DFM Strategy at SAAB Aerostructures

Within the aircraft industry, the use of composite materials such as carbon fiber reinforced plastics (CFRPs) is steadily increasing, especially in structural parts. Manufacturability needs to be considered in aircraft design to ensure a cost-effective manufacturing process. The aim of this paper is to describe the development of a new strategy for how SAAB Aerostructures addressing manufacturability issues during the development of airframe composite structures. Through literature review, benchmarking and company interviews, a design for manufacturing (DFM) strategy was developed. The strategy ensures that the important factors for successful DFM management are implemented on strategic, tactical and operational levels that contribute to a more cost-efficient product development process and aircraft design.