AIRBUS

Airbus unveils new thermoplastic aircraft fuselage design

In a step towards sustainable aviation, Airbus has unveiled an innovative fuselage design as part of the Clean Sky 2 initiative.

A thermoplastic fuselage demonstrator, assembled by the Airbus-led consortium, is helping experts to study disruptive materials and manufacturing methods. The aim is to speed up aircraft production, ultimately contributing to lowering aerospace’s carbon emissions.

This EU-backed public-private partnership aims to reduce aircraft CO2, nitrous oxides, and noise emissions by up to 30%, supporting the European Green Deal’s goal of achieving climate neutrality by 2050.

The centrepiece of this innovation is the Multifunctional Fuselage Demonstrator (MFFD), an 8m-long, 4m-wide fuselage section made primarily from thermoplastic composites, which are being tested for their viability as structural materials. Developed under the Large Passenger Aircraft platform of Clean Sky 2, the MFFD is expected to accelerate aircraft production and enhance the competitiveness of the European aerospace industry.

Airbus’ new fuselage design addresses the traditional challenges of aircraft assembly, where the fuselage must accommodate not only passengers and cargo but also vital systems such as electrical, mechanical, pneumatic, and hydraulic systems. These systems add significant weight and complexity to the production process. By utilising thermoplastics, Airbus has reduced the need for heavy fasteners, resulting in a lighter and more efficient fuselage.

The thermoplastic composites, known as carbon fibre-reinforced thermoplastic polymer composites (CFRTP), are mouldable at high temperatures and solidify upon cooling. This material innovation could lead to a structural weight saving of over 10% per aircraft, making the components easier to reuse and recycle compared to traditional metallic or carbon fibre parts.

The MFFD consists of two pre-equipped half-cylinder modules. The lower module includes systems and cabling, while the upper module contains some cabin monuments. These modules are assembled using advanced methods such as automated ultrasonic or laser spot-welding, which creates a cleaner assembly environment. The floor of the lower fuselage module is fixed in place by automated conduction welding.

By the project’s conclusion in late 2024, the MFFD had exceeded its weight-saving targets without increasing costs compared to traditional metallic fuselages. Over 40 technological advancements were tested, ranging from micromechanics to advanced welding techniques.

Airbus’ innovative methods could enable the production of up to 100 CFRTP composite fuselage units per month, meeting the demands of future single-aisle aircraft. This advancement promises economic benefits and aligns with Clean Sky 2’s objectives of reducing lifecycle emissions.

The MFFD is currently housed at the ZAL Centre of Applied Aeronautical Research in Hamburg, having been assembled at the Fraunhofer Institute near Stade. Airbus collaborated with 12 other major partners, including SAAB, GKN Fokker, and the German aerospace lab DLR, to bring this project to fruition.

“The MFFD is a fantastic example of what can be achieved if academia, research centres, and industry players align around a common objective,” said York Roth, leader of the Clean Sky 2 Large Passenger Aircraft platform at Airbus. “One player alone would never have been able to deliver such a complex large-scale demonstrator.”

This project underscores the potential of collaborative innovation in achieving significant advancements in aerospace technology and environmental sustainability.

Vivaero