Automated and Cost-efficient Production of Hybrid Sheet Moulding Compound Aircraft Components

Nowadays, innovative lightweight structures and highly complex aircraft components are made of modern lightweight materials such as carbon fibre reinforced plastics (CFRP). In this context current production technologies for fibre composite parts in aviation industry are generally characterised by long cycle times, sub-optimal material usage and a huge effort for reworking or finishing. A promising technology for the cost-efficient and time-saving manufacturing of lightweight, geometrically complex and functional components is the combination of thermoset Sheet Moulding Compounds (SMC) with chopped fibre reinforcements and pre-impregnated, tailored continuous fibre reinforcements in a single-stage compression moulding process. In comparison to conventional production technologies for composite materials this hybrid material and process technology obtains short cycle times, functional integration, a high freedom of design, an optimum material usage and less rework. For the manufacturing of cabin, cargo and also secondary structure aircraft components a direct implementation of metallic elements, such as inserts, and the use of recycled carbon fibres can be realised. Furthermore, this process technology can be fully automated to yield an increased economic efficiency.Hence, this paper deals with the potentials of this new technology, especially regarding to cost reduction and saving of time, by analysing and simulating the holistic process chain for the production of appropriate reference parts. In addition, different production concepts, with various grades of automation, are considered in detail and compared to each other in reference to determined criteria.