Pax Floor and Cargo Floor configuration based on a new manufacturing process here called Progressive Roll Forming (PRF) of Thermoplastic Carbon Reinforced Polymers (TPCRP) is presented. The process basically applies to seat rails and longerons. Raw material flows into the manufacturing device continuously; one or more plane sheets, are progressively heated, bended and compacted by rollers to achieve the desired shape i.e. C-Shape, J-Shape, H-Shape, etc. After floor grid configuration design and sizing, fixtures, jigs and moulds will be designed and manufactured for each component of the floor grid. In order to set up the new process, PRF equipment will be manufactured. Tools and fixtures for final assembly will be designed and manufactured, then the technological demonstrator i.e. test article floor grid will be manufactured.

Main innovative features are focused on cost saving due to process automation; this will enable the use of thermoplastics with consequent weight saving for Pax and Cargo Floor Grid and at the same time, recycling and maintainability features are improved giving a positive impact on environmental and life cycle management of the product.