The project aims to study a manufacturing and machining for very thick thermoplastic composite parts (8 to 35 mm). It will also correlate the process simulation results with the experimental results.

Project Achievements

The main achievements of the project were:

 

  • Development of an AFP strategy to address production rate and quality issues
  • Gap and overlap detection at bench scale and associated data analysis
  • Consolidation of parts with autonomous tooling
  • Optimised machining parameters and an analytical model
  • A multiphysics model to predict shape distortion after consolidation
  • Buttstrap demonstrator with compliant material health

Technical and economic impacts

The MATCH project has provided demonstration that use of thermoplastic composites on the engine pylon demonstrator is beneficial in terms of cost, performance (mass), and buy-to-fly ratio compared to the current titanium solution.

Applications & industrial perspectives

A new project was launched (MATCH II) in October 2022 to develop a manufacturing process for thermoplastic composite parts for use in primary aeronautical structures.

 

Essential levers and areas of work consistent with the continuity and complementarity of the MATCH project were identified in order to master the manufacture of thick composite parts while fully meeting industrial, economic and environmental constraints.

 

Two key areas of development were identified :

 

– Optimisation of tape laying by fibre placement machine and control over material health and geometry.

– Development of the process