CleanSky2 has addressed the development of new aircraft concepts and architectures including new materials and manufacturing. In this respect, Adaptive Multifunctional Test Rigs for Aeronautical Structures (AMTRAS project) will contribute to the CleanSky2 objectives with the development of innovative multifunctional Test Rigs, with high performance instrumentation and multishape capability ready to test structural behaviour of new materials (panels) and full-scale demonstrators (Tail unit) To achieve flexibility with multiaxiality and asynchronous loading conditions, AMTRAS will be built by: • A flexible parallel system based on hydraulic actuators. • Machine Vision based Non-contact deformation monitoring and measurement system • Non-Destructive Testing based on IR Thermography for the detection of structural defects The flexibility and accuracy provided by AMTRAS Test Rigs will contribute to time-to-market minimization, reducing the time span from concept to validated design. This is line with the topic JTI-CS2-2016-CPF03-AIR-02-22 since preparation and assembly of different multifunctional testing benches will no longer be necessary. In addition, AMTRAS contributes to one of the targeted achievements for defined in Challenge 2 “Maintaining and extending industrial leadership” FlightPath 2050 Goals in the Strategic Research & Innovation Agenda (SRIA) of ACARE (Advisory Council for Aviation Research and Innovation in Europe). According to the SRIA, innovation in aviation is complex, capital intensive and takes time, typically, 15 years can elapse between the generation of a concept and technology being fully developed for a specific application on the next generation of air vehicles. However, market demands shorter cycles of new technology integration, therefore greater efficiency in processes (design, test, validation, certification, manufacture) is demanded to facilitate faster and more frequent introduction of innovations addressing market needs.

ECO-CLIP project aims to demonstrate the technical, environmental and economic feasibility of manufacturing structural parts of aircrafts, specifically frame clips and system brackets, using recycled CF/LMPAEK obtained from factory waste. The overall approach of ECO-CLIP is to develop a short fibre recycled composite based on CF/LMPAEK, the manufacturing process for fabricating structural parts of aircraft (clips and brackets) and the welding technology for a success joining in a fuselage demonstrator avoiding fasteners. The whole product development process and manufacture technology will be validated by LCA/LCC studies. As final result, the new manufacturing processing route will be demonstrated as cost-effective and environmentally favorable by LCA and LCC studies. This can be understood in different stages: • Designing of recycling route to re-use material from factory waste • Material development: exploring different mixtures of %wt recycled %wt virgin CF/LMPAEK to accomplish the structural and mechanical requirements. • Design of manufacturing processes fulfilling the use case scenarios (clips and brackets) • Selected the joining technology for a MFFD • Assessment of developed technology through a study of ecological and economical impact The innovation results from ECO-CLIP project will comprise: development of a new composite material based on short fibre recycled CF/LMPAEK, optimised for injection moulding and 3D-printing, and methodology to redesign structural parts to be installed on a MFFD. These solutions will enable to validate the assessment of the technology, and the viability of the environmental and economical impact.

ADDIFLAP project’s general aim is the development of a new concept of flap track system by combining a novel flap track support manufactured by Laser Wire Direct Energy Deposition (W-DED-LB) with a new design of carriage system based in sliding pad concept, made using a self-lubricant MMC coating. Deployment of W-DED-LB process will be supported by numerical models to reduce the distortion effect on the final flap track structure and establish the manufacturing strategies for process manufacturing and by online process monitoring & control. Sliding pad design for the flap carriage system will be based on self-lubricant surfaces approach. ADDIFLAP involves the following objectives: • Development of simulation models and optimized manufacturing strategies will reduce the effort in reducing the distortion on the flap track support up to 50% regarding the trial-and-error approach. This will impact in the time to market, reducing even further the time from design to manufacturing. • Flexibility (on design, enabling part consolidation…) provided by AM technologies (W-DED-LB) will enable to reduce the time to market into 20%. • Reduction of 60% on material waste regarding conventional manufacturing is expected (Reduction of the BTF ratio). • Reduction of 20-30% on component distortion will be achieved by combination of simulation, and optimization of WDED-LB process parameters and online monitoring & control developed in ADDIFLAP Project. • The sliding carriage system will increase the component flying hours for a conventional Business Jet in a factor of two regarding conventional roller system. The technology developed in ADDIFLAP will enable the design of a multifunctional flap which combines aileron and high lift functions in one flap body having direct impact on weight reduction.

Evaluation of LAminate composite Distortion by an Integrated Numerical-Experimental approach The consortium is proposing a method to evaluate the distortion of laminate composites in a number of scenarios, starting from test coupons manufacturing, measurements of distortion and correlation to the numerical tool that will evaluate a sub-scale demonstrator and in the end a full 7 meter composite wing.