Abstract: An aircraft empennage includes a vertical tail plane, a rear fuselage section attached to the vertical tail plane and including a skin and internal reinforcing members, a horizontal tail plane comprising two lateral torsion boxes and a framework located between the two lateral torsion boxes comprising a front spar, a rear spar and two ribs extending between the front and the rear spar and each adjacent to a lateral torsion box. The framework encloses a portion of the vertical tail plane along its spanwise direction. The aircraft empennage includes an attachment assembly attaching the framework to the rear fuselage section, the attachment assembly crossing the skin and extends between the internal reinforcing members of the rear fuselage section and the framework.

Abstract: Tooling for manufacturing multi-spar torsion boxes with different web heights, the tooling includes a mandrel module having a hollow beam geometry which comprises a first base and a second base opposite to the first base, and two walls extending between said first base and said second base, and at least one spacer module configured for coupling with the mandrel module, wherein the web height of a multi-spar torsion box is defined by the coupling between the mandrel module and at least one spacer module. A method for manufacturing multi-spar torsion boxes with different web heights.

Abstract: A method for manufacturing the trailing edge ribs and the bearing ribs of trailing edges of aircraft lifting surfaces, in which the trailing edge ribs and the bearing ribs are made by joining simple C-shaped parts and/or simple L-shaped parts so as to obtain the final trailing edge ribs and bearing ribs. The manufacturing of the simple C-shaped parts uses the same tooling both for the trailing edge ribs and the bearing ribs, and the manufacturing of the simple L-shaped parts uses the same tooling both for the trailing edge ribs and the bearing ribs.

Abstract: An aircraft empennage includes a vertical tail plane, a rear fuselage section attached to the vertical tail plane and including a skin and internal reinforcing members, a horizontal tail plane comprising two lateral torsion boxes and a framework located between the two lateral torsion boxes comprising a front spar, a rear spar and two ribs extending between the front and the rear spar and each adjacent to a lateral torsion box. The framework encloses a portion of the vertical tail plane along its spanwise direction. The aircraft empennage includes an attachment assembly attaching the framework to the rear fuselage section, the attachment assembly crossing the skin and extends between the internal reinforcing members of the rear fuselage section and the framework.

Abstract: A method for manufacturing, layer-upon-layer, an integral composite aeronautical structure, wherein the method comprises: (a) providing an additive manufacturing tool comprising a depositing mold shaping an aerodynamic surface and at least one head configured to be moved over the depositing mold and to deposit fibrous material reinforcement and/or meltable material; (b) depositing fibrous material reinforcement embedded within meltable material onto the depositing mold, at least one layer of a lower aerodynamic face-sheet being built thereby; (c) depositing meltable material onto at least a portion of the outer layer of the lower aerodynamic face-sheet, at least one layer of core structure being built thereby; and (d) depositing fibrous material reinforcement embedded within meltable material onto at least the outer layer of the core structure, at least one layer of an upper aerodynamic face-sheet being built thereby; wherein steps (b), (c) and (d) are performed using Additive Manufacturing technology.

Abstract: Tooling for manufacturing multi-spar torsion boxes with different web heights, the tooling includes a mandrel module having a hollow beam geometry which comprises a first base and a second base opposite to the first base, and two walls extending between said first base and said second base, and at least one spacer module configured for coupling with the mandrel module, wherein the web height of a multi-spar torsion box is defined by the coupling between the mandrel module and at least one spacer module. A method for manufacturing multi-spar torsion boxes with different web heights.

Abstract: A composite structure (1) for an aircraft, having at least one insert (2) for receiving attachment devices, each insert (2) includes a core (3) having a major dimension and containing at least one through-hole (4), and a composite strip arrangement formed by a first section (5) surrounding the core (3) and attached to said core (3) by an adhesive polymeric layer, and a second section (6) including at least one free end (6a). The first (5) and the second portion (6) of the composite strip arrangement are disposed over a first surface (1a) of the composite structure (1), such that the major dimension of the core (3) is positioned transversal to said first surface (1 a). The at least one insert (2) is co-cured with the composite structure (1).

Abstract: A tip structure for an aircraft airfoil, such as a control surface (ailerons, flaps, elevators, rudders, etc) and/or a lifting surface (wings, HTP's, VTP's) is a unitary body and includes a tip shell and a metallic material on the outer surface of the tip shell suitable to withstand a lighting strike. The tip shell has been obtained by a single-stage injection molding process using a thermoplastic composite material having fibers dispersed therein, and the metallic material has been integrally formed with the tip shell.

Abstract: An aircraft aerodynamic surface (1) including a torsion box (2) having a front spar (21) and rear spar (22), a first control surface (3) including a front spar (31) and a trailing edge (32) and a second control surface (4) having a front spar (41), a trailing edge (42), and a pivot device (5, 6, 7, 8) for pivotally attaching the first control surface (3) and the second control surface (4) to the rear spar (22) of the torsion box (2), the first control surface is an inboard control surface (4) including two lateral ribs (9, 9?), six inner ribs (11, 12, 13, 14, 15, 10) and an inner spar (16), and the second control surface (3) is an outboard control surface which includes two lateral ribs (20, 20?), three internal ribs (17, 18, 19), two internal spars (24, 24?) and one internal spar (23).

Abstract: A leading edge section with laminar flow control includes: a perforated outer skin, a perforated inner skin, and a plurality of suction chambers formed between the outer skin and the inner skin. The leading edge section includes a plurality of stringers span-wise arranged at the leading edge section, and integrally formed with the outer skin, such that the inner skin is joined to the stringers. A method for manufacturing a leading edge section integrating a laminar flow control system is described, wherein a perforated inner skin is joined with a perforated outer skin having a plurality of stringers integrally formed with the outer skin, such that suction chambers are defined by a part of the outer skin, a part of the inner skin and a pair of stringers.

Abstract: A method for manufacturing the trailing edge ribs and the bearing ribs of trailing edges of aircraft lifting surfaces, in which the trailing edge ribs and the bearing ribs are made by joining simple C-shaped parts and/or simple L-shaped parts so as to obtain the final trailing edge ribs and bearing ribs. The manufacturing of the simple C-shaped parts uses the same tooling both for the trailing edge ribs and the bearing ribs, and the manufacturing of the simple L-shaped parts uses the same tooling both for the trailing edge ribs and the bearing ribs.

Abstract: This disclosure relates to the manufacturing of a leading edge section with hybrid laminar flow control for an aircraft. A manufacturing method involves: providing an outer hood, a plurality of elongated modules, first and second C-shaped profiles having comprising cavities, and an inner mandrel; assembling an injection molding tool by placing each profile on each end of the inner mandrel, arranging a first extreme of each elongated module in one cavity of the first profile and a second extreme of the module in another cavity of the second profile, both cavities positioned in the same radial direction; and placing the hood on first and second profiles to close the tool. Further, the injection molding tool is closed and filled with an injection compound comprising thermoplastic and short-fiber. Finally, the compound is hardened and demolded.

Abstract: A method for manufacturing, layer-upon-layer, an integral composite aeronautical structure, wherein the method comprises: (a) providing an additive manufacturing tool comprising a depositing mold shaping an aerodynamic surface and at least one head configured to be moved over the depositing mold and to deposit fibrous material reinforcement and/or meltable material; (b) depositing fibrous material reinforcement embedded within meltable material onto the depositing mold, at least one layer of a lower aerodynamic face-sheet being built thereby; (c) depositing meltable material onto at least a portion of the outer layer of the lower aerodynamic face-sheet, at least one layer of core structure being built thereby; and (d) depositing fibrous material reinforcement embedded within meltable material onto at least the outer layer of the core structure, at least one layer of an upper aerodynamic face-sheet being built thereby; wherein steps (b), (c) and (d) are performed using Additive Manufacturing technology.

Abstract: A composite structure (1) for an aircraft, having at least one insert (2) for receiving attachment devices, each insert (2) includes a core (3) having a major dimension and containing at least one through-hole (4), and a composite strip arrangement formed by a first section (5) surrounding the core (3) and attached to said core (3) by an adhesive polymeric layer, and a second section (6) including at least one free end (6a). The first (5) and the second portion (6) of the composite strip arrangement are disposed over a first surface (1a) of the composite structure (1), such that the major dimension of the core (3) is positioned transversal to said first surface (1 a). The at least one insert (2) is co-cured with the composite structure (1).

Abstract: A tip structure for an aircraft airfoil, such as a control surface (ailerons, flaps, elevators, rudders, etc) and/or a lifting surface (wings, HTP's, VTP's) is a unitary body and includes a tip shell and a metallic material on the outer surface of the tip shell suitable to withstand a lighting strike. The tip shell has been obtained by a single-stage injection molding process using a thermoplastic composite material having fibers dispersed therein, and the metallic material has been integrally formed with the tip shell.

Abstract: A structure of a control surface for aircrafts, such as elevators, rudders, landing flaps, ailerons, and other similar lifting surfaces. The control surface includes a front spar, a rear spar, a plurality of ribs, at least one hinge fitting, and at least one actuator fitting, the hinge and actuator fittings joined with the front spar. A first rib is joined with a hinge fitting to form a first oblique angle with the front spar; a second rib is joined with an actuator fitting to form a second oblique angle with the front spar. The rear spar, located between the front spar and trailing edge of the control surface, extends only between the second rib and an outboard end of the control surface. The ribs are located in correspondence with the main torsion and bending load paths created in the control surface during flight, landing or takeoff.

Abstract: An aircraft aerodynamic surface (1) including a torsion box (2) having a front spar (21) and rear spar (22), a first control surface (3) including a front spar (31) and a trailing edge (32) and a second control surface (4) having a front spar (41), a trailing edge (42), and a pivot device (5, 6, 7, 8) for pivotally attaching the first control surface (3) and the second control surface (4) to the rear spar (22) of the torsion box (2), the first control surface is an inboard control surface (4) including two lateral ribs (9, 9?), six inner ribs (11, 12, 13, 14, 15, 10) and an inner spar (16), and the second control surface (3) is an outboard control surface which includes two lateral ribs (20, 20?), three internal ribs (17, 18, 19), two internal spars (24, 24?) and one internal spar (23).

Abstract: An aircraft aerodynamic surface includes a torsion box having an upper skin, a lower skin, and a front spar, and a leading edge having an external shell and an impact resisting structure. The external shell may be shaped with an aerodynamic leading edge profile, being configured to provide Laminar Flow Control (LFC) to the leading edge. The impact resisting structure is spanwise arranged between the external shell and the front spar, and is configured for absorbing a bird strike to prevent damage in the front spar. Also, at least one of the external shell and the impact resisting structure is fitted with the upper and lower skins of the torsion box to thereby facilitate leading edge exchange.

Abstract: This disclosure relates to the manufacturing of a leading edge section with hybrid laminar flow control for an aircraft. A manufacturing method involves: providing an outer hood, a plurality of elongated modules, first and second C-shaped profiles having comprising cavities, and an inner mandrel; assembling an injection moulding tool by placing each profile on each end of the inner mandrel, arranging a first extreme of each elongated module in one cavity of the first profile and a second extreme of the module in another cavity of the second profile, both cavities positioned in the same radial direction; and placing the hood on first and second profiles to close the tool. Further, the injection moulding tool is closed and filled with an injection compound comprising thermoplastic and short-fiber. Finally, the compound is hardened and demoulded.

Abstract: A leading edge section with laminar flow control includes: a perforated outer skin, a perforated inner skin, and a plurality of suction chambers formed between the outer skin and the inner skin. The leading edge section includes a plurality of stringers span-wise arranged at the leading edge section, and integrally formed with the outer skin, such that the inner skin is joined to the stringers. A method for manufacturing a leading edge section integrating a laminar flow control system is described, wherein a perforated inner skin is joined with a perforated outer skin having a plurality of stringers integrally formed with the outer skin, such that suction chambers are defined by a part of the outer skin, a part of the inner skin and a pair of stringers.