This innovation promises to revolutionize how the next generation of high-rate aircraft are built, addressing critical industry demands for efficiency and scalability.
The aerospace industry is poised for a significant leap forward in manufacturing efficiency and sustainability, thanks to the HELUES project. Unveiled at the prestigious Paris Air Show, this multi-partner collaboration, spearheaded by leading materials companies Arkema and Hexcel, presented a sophisticated demonstrator: a complex structural component for an overwing emergency exit door, produced using revolutionary thermoplastic solutions.
The HELUES project is the culmination of a strategic alliance formed in 2018 between Hexcel, a specialist in carbon fiber, and Arkema, renowned for its PEKK (Polyetherketoneketone) expertise. Their combined knowledge has been instrumental in developing thermoplastic composite solutions tailored for the demanding aerospace sector. At the Paris Air Show, Hexcel prominently featured its advancements by showcasing the highly innovative PEKK/carbon thermoplastics component, a tangible result of the HELUES project's efforts.
As the global demand for more efficient and scalable aircraft manufacturing continues to surge, particularly for single-aisle jets, Hexcel and its HELUES partners are actively addressing the pressing production challenges faced by Original Equipment Manufacturers (OEMs). This is achieved through the introduction of novel material and process innovations that promise to reshape the future of aerospace production.
Central to the HELUES technology is a pioneering one-step forming and injection overmolding process. This ingenious method leverages HexPly® unidirectional (UD) carbon fiber-reinforced Kepstan® PEKK tapes in conjunction with Kepstan® PEKK injection molding compounds. The integrated approach facilitates the rapid creation of a fully formed, structurally complex component, complete with reinforcing ribs and functional elements, in an astonishingly short time – less than two minutes.
This thermoplastics technology offers a trifecta of significant advantages for aerospace OEMs:
• Dramatically Shortened Cycle Times: Production cycles are reduced from hours to mere minutes, enabling the industry to meet ambitious production targets of up to 80-100 jets per month.
• Greater Design Flexibility and Weight Savings: The inherent ability of thermoplastics to be reshaped and welded, rather than traditionally fastened, allows for more intricate designs and substantial weight reductions, contributing to improved fuel efficiency.
• Enhanced Sustainability and Recyclability: Unlike thermoset composites, thermoplastics can be reprocessed and reused, aligning perfectly with the aerospace industry's growing commitment to environmental responsibility and circular economy principles.
The HELUES demonstrator serves as a powerful testament to these benefits. It directly replaces a conventionally assembled door structure with a single, integrated part, leading to a remarkable reduction in component count and assembly steps by up to 90%. Early-stage testing has further validated the viability of this innovation, confirming excellent material bonding between the molded ribs and thermoformed laminates, a crucial factor for components operating in challenging aerospace environments.
