THyGr

Thermoplastic hybrid design for complex structural components in large-scale aerospace production

Efficient, electrically powered flight systems are essential for climate-friendly air transportation and social acceptance of urban air mobility. One example is the Lilium Jet with pivoting electric drives for vertical take-offs and landings. The highly complex structural drive units (flaps) require economical production processes for five-digit quantities. Thermoplastic hybrid structures, proven in the automotive industry, combine organosheets, FRP profiles and injection molded parts in an automated process with production times of less than two minutes. High process integration reduces assembly, quality assurance and documentation costs. Thermoplastics also enable waste-free production, recycling and reuse. The THyGr project is researching process design with certified high-performance thermoplastics, recycling-friendly design and inline quality assurance. Simulations accelerate development, AI-supported quality assurance optimizes processes and industrial demonstrations minimize risks. Sustainability is integrated throughout the entire development process, with a focus on recycling offcuts and a life cycle assessment study to save resources.