DLR: Pioneering Sustainable Materials for Aerospace

At the German Aerospace Centre (DLR), they are involved in the development of Use Case 4 with various project partners. This Use Case originates from the aerospace industry and deals with the production of an access panel for a training aircraft. The component is currently made of carbon fibre reinforced epoxy resin and contains an internal honeycomb structure. This design not only places high demands on production, but also presents significant challenges in terms of carbon footprint and recyclability.

To meet these challenges, they are working to develop an alternative structure based on a thermoplastic composite of flax fibre and PA11. The aim is to significantly improve the environmental footprint of the component by using bio-based and recyclable materials.

Their role in the project includes the development of suitable production routes and the definition and implementation of testing procedures. They are analysing and developing both existing and new manufacturing and recycling methods. In the “Testing, validation and assessment” work package, they are taking the lead and coordinating the work of all the partners involved. Their aim is to develop standardised and reliable testing and validation methods. They support the mechanical and non-destructive testing of materials and components and help to establish an overarching standard in the project.

Figure 1: DLR Hot press for manufacturing of prototypes

Figure 2: First organo sheets for further process development