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Design of sandwich structures for sensor integration, optimisation and manufacturing of sandwich core

European Union
Complete with results
Geo-spatial type
Total project cost
€77 000
EU Contribution
€41 073
Project Acronym
STRIA Roadmaps
Vehicle design and manufacturing (VDM)
Transport mode
Airborne icon
Transport policies
Environmental/Emissions aspects,
Transport sectors
Passenger transport,
Freight transport


Call for proposal
Link to CORDIS

Evonik proposed to contribute to the evaluation of the strength of foam sandwich structures, as demanded in the Call for Proposal (CfP), by providing a failure criterion, which has been designed specifically for ROHACELL® foams in cooperation with the German Institute for Polymers (DKI) in Darmstadt. This criterion had been proved to deliver very accurate results in static FE calculations and might be used as a basis for extension to calculate impact and fatigue loads.

Evonik has profound knowledge and experience in the field of manufacture and supply of raw and shaped foam core materials meeting the requirements of the aerospace industry, which Evonik proposes to supply as demanded in the CfP. Evonik has the facilities to produce raw foam cores as well as to shape these cores to the desired geometry, e. g. by using cutting and CNC machining equipment. Furthermore Evonik possesses the infrastructure needed for the quality control and documentation which is mandatory for aircraft applications. ROHACELL® foams offer superior heat and pressure stability up to 180°C and 7 bar as well as a one hundred percent closed cell structure, which eliminates excessive resin absorption and thus reduces overall weight. Evonik possesses an autoclave, which is proposed be used for the manufacture of sandwich panels, e.g. using prepreg face sheets. Evonik proposed to contribute to the development of special design rules considering SHM-requirements, as demanded in the CfP.


Parent Programmes
Institution Type
Public institution
Institution Name
European Commission
Type of funding
Public (EU)
Specific funding programme
JTI-CS - Joint Technology Initiatives - Clean Sky
Other Programme
JTI-CS-2009-1-GRA-01-013 Design of sandwich structures for sensor integration, optimisation and manufacturing of sandwich core


Executive Summary:

The goal of the project was the design and manufacture of carbon fibre reinforced plastic (CFRP) sandwich structures with embedded Structural Health Monitoring (SHM) sensors. This goal was reached.

Suitable ROHACELL foam cores were designed and machined. An autoclave was used to manufacture demonstrator parts. Fibre optical bragg gratings (FOBG) were chosen as SHM system, the demonstrator parts were designed as profile stiffened shells with foam-filled omega profiles. The performance of the FOBG in the cured demonstrator parts was shown.

It was concluded that the implementation of SHM systems in profile stiffened shells is feasible. SHM systems integrated in structurally loaded aircraft parts can lead to a significant reduction of safety factors, thus reducing weight and decreasing fuel consumption. Furthermore SHM systems would allow for a reduction of maintenance effort.

The project consortium consisted of the single member Evonik Röhm GmbH, Kirschenalle, D-64293 Darmstadt.



Lead Organisation
Evonik Rohm Gmbh
Kirschenalle 45, 64293 Darmstadt, Germany
EU Contribution
€41 073
Partner Organisations
EU Contribution


Technology Theme
Sensor technologies
Integrated sensors for structural components
Development phase
Demonstration/prototyping/Pilot Production
Technology Theme
Condition monitoring
Sensor condition monitoring system
Development phase
Demonstration/prototyping/Pilot Production

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