A milestone in aerospace manufacturing

The MFFD is the result of ten years of research carried out by a consortium of 12 European organizations. The project’s goal has been to create a large-scale fuselage structure made entirely of thermoplastics (TPC), an innovative material within the composites sector. For its construction, thermoplastic welding has been used, a technique that optimizes production processes, reduces costs and manufacturing times, and also decreases the need for manual labor.

One of the key aspects of this development is the reduction of the aircraft’s weight, leading to lower fuel consumption and a significant decrease in CO₂ emissions, contributing to more sustainable aviation.

CT Engineering, a key player in the development of the MFFD

CT Engineering has played a fundamental role in the success of the MFFD, leading the MultiFAL (2019-2023) and WELDER (2021-2023) projects and coordinating the consortium.

MultiFAL focused on the development of an automated assembly plant for joining the upper and lower halves of the fuselage. WELDER, on the other hand, designed and developed two modular welding solutions based on robots, to finish joining the right fuselage and then assemble the upper and lower frames.

The project also received collaboration from specialized entities such as AIMEN Technology Centre (O Porriño), Aitiip Technology Centre (Zaragoza), Dukane (ultrasonic technology experts), and FFT (process automation specialists), whose contributions were essential in achieving the MFFD’s goals.

Recognition for innovation in the aerospace industry

The award received at JEC World emphasizes the importance of the MFFD as a benchmark in aerospace innovation and highlights the contribution of CT Engineering in the development of technologies that optimize manufacturing processes. This recognition underscores the company’s commitment to excellence, efficiency, and sustainability in the aerospace sector.

Acknowledgement

• MultiFAL & WELDER projects have received funding from the Clean Sky 2 Joint Undertaking (JU). The JU receives support from the European Union’s Horizon 2020 research and innovation programme and the Clean Sky 2 JU members other than the Union.

Disclaimer

• The results, opinions, conclusions, etc. presented in this work are those of the author(s) only and do not necessarily represent the position of the JU; the JU is not responsible for any use made of the information contained herein.