The ‘design for manufacture’ of continuous fibre-reinforced thermoplastic products in primary aircraft structure

As the technology of composite structures matures, the use of thermoplastic composite materials in aircraft increases, offering reduced structural weight and improved payload. However, primary load-bearing applications demand optimum structural integrity in harsh environmental conditions, and the total installed manufacturing cost has previously restricted the use of thermoplastic materials. This paper describes a programme of work to develop a carbon fibre-reinforced thermoplastic transverse floor beam for a commercial jet. Component selection, material selection, design optimization, equipment, processing methods and testing are discussed. A cost model for the composite component is presented in comparison with that of the incumbent aluminium alloy beam. A key element of the work has been “design for manufacture”.