Lightweight solution of product in ultralight aircraft

Purpose and goal:

An innovative solution for manufacturing a composite component and introducing a joint bearing in the process. This was done to reduce manufacturing steps, cost, and climate impact. The change of material reduces the weight of the component and the casting of the component together with the joint bearing.

Further investigations is needed to measure the total climate impact due to the change of material. The concept of introducing the joint bearings in the process show good results. However, further investigations on mechanical properties are needed. Expected results and effects:

The concept of introducing joint bearing or other components directly in the forming process where the tool maintains an elevated temperature proves to be possible and provides indications that it is worth continuing studies to be able to apply the technology in a process flow. Next steps to achieve the goals are to further investigate the geometry while maintaining strength.

Compression molding can be an obstacle for the selected component, at low series, which gives a higher product price and require other solutions, such as 3D printing, with other solutions for design / construction. Approach and implementation:

The project worked by continuous contact between the partners where the material and geometry of the product was discussed. When a design was introduced, Blackwing performed mechanical calculations. These steps were iterated a couple of times and to be able to perform the other activities a simplified prototype was selected, and a forming tool was constructed. The concept of introducing the joint bearing was performed with good results and the component was tested using Blackwings test setup.