Thermoforming City Flyer on the Rise—3000 Times Faster Production Compared to Metal

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Krauss Maffei and the National Institute for Aviation Research (NIAR) at Wichita State University, USA, have developed a structural component with a ribbed structure using the Fiber-Form process, specifically designed for eVTOL aircraft—electrically powered flying devices capable of vertical takeoff and landing. The manufacturing time has been reduced from over 100 hours to just two minutes compared to the metal version.

In the Fiber-Form process, a so-called organosheet, thermoplastically impregnated continuous fibers, is placed into the mold, shaped, and overmolded. Compared to manufacturing components from metal, this fully automated combination of thermoforming and thermoplastic overmolding offers significant advantages such as lower costs, reduced weight, and a fraction of the time required. And this comes with the same mechanical strength and safety. At the same time, the Fiber-Form process allows significantly more design freedom.

At the NIAR "Advanced Technologies Lab for Aerospace Systems" (ATLAS), this is done on a GXW 450-2000/1400 from KraussMaffei with a clamping force of 4500 kN, a rotary unit, and a suitable automation solution with two IR industrial robots.

In contrast, the thermoplastic component was formed and overmolded from a flat organosheet in less than two minutes. The proven expertise of the involved partners was crucial for this success.

Dr. Waruna Seneviratne

3000 Times Faster Production Than With Metal

The short cycle times compared to metal are particularly evident with the newly developed and tested ribbed structure. Traditionally, components of this type are milled from a solid metal block—a process that removes more than 80 percent of the material and takes over 100 working hours. "In contrast, the thermoplastic component was formed and overmolded from a flat organosheet in less than two minutes. The exceptional expertise of the involved partners was crucial to this success," explains Dr. Waruna Seneviratne, Director of NIAR ATLAS. Besides Krauss Maffei, the companies Joby Aviation, Toyota, Victrex, and Prospect were involved in the development. The project is part of the "Manufacturing for Affordable Sustainable Composites" program of the Air Force Research Laboratory.

The results highlight the potential of the Fiber-Form technology, known from the automotive industry, for the series production of primary and secondary structures in aviation.

Dr. Waruna Seneviratne

Benefiting from Aautomotive Mass Production

"The results highlight the potential of the Fiber-Form technology, known from the automotive industry, for the series production of primary and secondary structures in aviation," Seneviratne continues. Eugen Schubert, Sales and Applications Manager, IMM & Automation at KraussMaffei, emphasizes the importance of the NIAR ATLAS laboratory as an innovation platform: "The NIAR ATLAS Institute provides an ideal environment where machine manufacturers, material suppliers, and tool developers can work together with aircraft manufacturers to test new materials and processes risk-free for demanding aviation applications and develop them for serial production."

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Continuation of the Success Product "Prachter"

NIAR ATLAS and KraussMaffei successfully collaborated back in 2024. At that time, the focus was on window closures manufactured using the Fiber-Form process, which were used for the conversion of passenger aircraft to cargo aircraft, known as "Prachter." The window closures were produced in just 90 seconds and were 20 to 30 percent lighter and only half as expensive as their metal counterparts.

With the new, complex rib structure, the development partners now showcase the Fiber-Form technology on a sophisticated structural component, paving the way for further applications and successful certification in aviation.

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