TOSCA

Manufacturing Processes and Digital Tools for More Sustainable Composite Aerostructures

Lightweight components made from composite materials are a key element to increase the efficiency of aircraft. However, there are persistent problems with the recycling of such materials. The TOSCA project thus aims at the development of a processing chain for new epoxy vitrimer resins, which have the mechanical performance of conventional thermoset resins, but allow the more efficient recycling. This type of resin is already taking the first steps towards certification and there is a need to develop the related production processes.

The TOSCA project will investigate a whole processing chain, including lay-up by automated fibre placement, curing, re-work, maintenance and repair. This processing chain will be supported by digital tools to acquire data through integrated inspection systems and through sensors for structural health monitoring, that are embedded in critical areas of the part. All these data will be used to iteratively improve production, aiming at a zero-defect manufacturing process.

The consortium consists of research partners and industry covering all the processing steps. All of the research organisations are linked to industrial partners to ensure a proper take-up of the results by industry after the end of the project. About 2000 companies including OEMs and Tier-1 suppliers in Europe in the field of composite parts manufacturing (mainly structural parts) as well as machine building companies will benefit from the results. Interaction with Clean Aviation has taken place and will continue in TOSCA to ensure that the developments fit into the long-term roadmaps of the European aviation industry.