Cevotec joins Airbus-led R&D on thermoplastic CFRP frames

Author: Dr. Florian Lenz, Technical Director Cevotec | Publish date: 22.10.2025

In an Airbus‑led consortium, Cevotec contributes Fiber Patch Placement (FPP) preforming expertise to a three‑year feasibility and maturation project on thermoplastic CFRP fuselage structures.

Cevotec participates in an Airbus‑led research and development consortium within the German aerospace research program “LuFo VII-1”, focused on developing a high rate manufacturing route for thermoplastic CFRP fuselage structures. The three‑year program, launched in 2025, centers on technology route development and validation. The consortium comprises Airbus (Lead), the German Aerospace Center (DLR), Fraunhofer institutes IGCV, ICT and IFAM, the Leibnitz Institute IVW and Cevotec. Cevotec contributes FPP preform expertise for off‑axis  (±45°/90°) ply lay-up for fuselage frames, providing a technology module for a future integrated process chain that also includes automated 0° ply lay-up, stamp‑forming, and trimming. The shared goal is clear: reduce weight, increase layup rates, and develop a scrap‑lean process chain that can support future production of more than 75 single-aisle aircraft per month.

Fuselage frames and the case for thermoplastic CFRP

Fuselage frames are a key component of the airframe. They carry loads, stabilize the skin, and create the interfaces to systems and cabins. Traditionally, these frames are metallic or made with thermoset composites. Thermoplastic CFRP adds a compelling alternative: weldability, faster processing, inherent toughness, and proven pathways to repair and recycling. Those benefits come with manufacturing challenges, driven by those materials’ inertness at room temperature. Unlike thermoset prepregs, which usually exhibit a certain stickiness (“tack”), non-tacky thermoplastic prepregs can’t merely be stacked as preparation for curing, but have to be preformed using high (local) temperatures for lamination and (pre-) consolidation.

The goal: A high-rate process combining FPP, AFP and stamp forming

The  project team intends to build-up the modules of a future integrated process chain, purpose‑built for rate and repeatability. Cevotec’s robots place off‑axis patches (±45°/90°) to form complete stacks (see Figure 1).0° plies that carry axial loads efficiently will be placed by Fraunhofer IGCV using thermoplastic AFP technology. Airbus then takes over with stamp‑forming: The preforms are heated and shaped in seconds, followed by trimming and downstream finishing.

The process is digitally defined and traceable; placement data can be used to verify that fiber orientations and locations match design intent. An AI-driven vision system to monitor the accuracy of placement will be investigated. Those will be building blocks of a “first‑time‑right” process that minimizes scrap and stabilizes quality across shifts and manufacturing sites.

Rate, cost and sustainability drive composites for next single-aisle program

The project is guided by an ambitious set of outcomes. First, weight: moving to CFRP frames is a direct lever on reducing airframe mass, resulting in lower fuel burn and emissions over the aircraft’s life. Second, rate: each step – from placement to forming – must fit a takt‑time‑driven environment capable of supporting more than 75 aircraft per month. Third, cost and sustainability: by combining precise patch placement with robust forming, we are targeting a step‑change reduction in production scrap and a path to circularity enabled by thermoplastics.

High-rate off-axis: The case for Fiber Patch Placement (FPP)

For the intended process chain, FPP is expected to achieve higher lay‑up rate than AFP for off‑axis plies on complex geometries. AFP remains the efficient choice for the curved, continuous 0° layers, while FPP is applied to lay-up the non-zero (i.e. “off-axis”) plies. In one fast placement operation, a wide patch with the desired fiber orientation can be placed. Compared to multiple AFP placement operations required to cover the same width, FPP offer the opportunity to improve cycle and takt time, thereby process economics and rate capability.

Getting to action: SAMBA on frame structures

The HERA project focusses on validating technology modules for a high-rate thermoplastic process chain for future aircraft structures. To develop and validate the FPP module, Cevotec will modify and expand the capabilities of their SAMBA Step L lab system (Figure 2). This equipment offers a high flexibility to integrate project-developed sub-modules, while benefiting from general precision placement of larger plies as validated in previous aerospace projects.

Outlook

With the start of the project in August 2025, we embarked on this journey to apply FPP technology for next-gen thermoplastic aircraft structures. We’re excited for what’s ahead of us, and motivated to go further. Stay tuned for the next project updates – and get in contact to discuss your project ideas!

Acknowledgements:

This research program is supported by the Federal Ministry for Economic Affairs and Energy (BMWE) under the support code 20W2405E.