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case study

Cellular core tech for Airbus

R&D project to reduce costs and time in the wing manufacturing process

The context

According to OEMs’ new challenges concerning their wing structures, the need to boost efficiency, productivity and cost reduction is essential in processing methods. The management of non-conformance and the heavy weight of some parts can prove an important issue. It is a real challenge to integrate manufacturing of lightweight structure in a one-shot process in order to reduce costs and save production time.

The project

To help optimise the wing structure design and processing methods, Expleo has worked on a composite design, tooling and processing methods that uses sacrificial pressurised thermoplastic cores. This unique process allows clients to create complex composite structures in an integrated one-shot process. In partnership with Aerosud Technology solutions, Expleo has considerably reduced costs and time in the wing manufacturing process. This new opportunity allows clients to eliminate the need for secondary fasteners and vaccuum bagging process. The design and prototyping can be done with a 3D printer.

Expleo’s expertise in action

  • Stress analysis and engineering
  • Design analysis and engineering
  • Partnership with Aerosud for manufacturing

What’s next?

Cellular Core Technology can also be applied to the space and automotive industries as well as gas and oil sectors. The aim is to implement this concept with different type of materials and use robotic platforms for manufacturing.

Contact us for more information on R&D projects at Expleo.

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Expleo enlivens a full R&D and innovation ecosystem (engineers, laboratories, start-ups, universities) to explore emerging technologies and create new business applications.