Successful completion of the LuFo VI CertiFlight project at TU Dresden

In September 2025, the Chair of Aircraft Technology at TU Dresden successfully completed the LuFo VI-1 joint project CertiFlight (End-to-end digital quality assurance chains for innovative certification processes using the example of additive manufacturing technologies) and the associated sub-project of TU Dresden (Numerical methods for predicting the structural mechanical properties of additively manufactured aircraft components, taking imperfections into account) as part of a consortium meeting.

Together with project partners IMA Materialforschung und Anwendungstechnik GmbH, Fraunhofer IVI, inquence GmbH, BTU Cottbus-Senftenberg und AM Metals GmbH great progress and successes were achieved over the four-year period in the areas of additive manufacturing using the LPBF process, testing, certification and quality assurance, and the simulation of the structural behaviour of metallic additively manufactured aircraft components.

The CertiFlight project focuses on the digital certification platform. Using the example of the demanding certification process for aircraft components, this was implemented digitally from the project idea to process data-based, AI-supported quality assurance during series production and made accessible on a web-based platform. Development and manufacturing companies, regulatory authorities and testing institutes are users and contribute to the certification project with the help of the platform. Simulation and data analysis modules developed during the project are part of the platform and facilitate the entire certification process.

The results were presented at international conferences and trade fairs during the project period and published in international journals.

© ILR TU Dresden

We would like to express our sincere thanks for the excellent cooperation with and among all project partners, the DLR Project Management Agency for Aeronautics Research and the Federal Ministry for Economic Affairs and Energy.

© BMWE

The CertiFlight joint project was funded by the Federal Ministry for Economic Affairs and Climate Protection under grant number 20D1925E. The authors are responsible for the content of this publication.

Publications

1. Rümmler et al.: Study of the influence of additive manufacturing applicable surface treatment methods on mechanical part properties for use in aerospace applications, 2024

2. Holfeld et al.: An Application of AI for Online Estimation of the Impact of Imperfections in Additive Manufactured Components

3. Neumann et al.: A data-based certification approach for additively manufactured metal aircraft components, 2025

4. Mauersberger et al. „Topology optimization of a benchmark artifact with target stress states using evolutionary algorithms“, 2024

5. Mauersberger et al. „Scaling-up topology optimization with target stress states via gradient-based algorithms“, 2025