The demand for composite materials in aerospace is increasing, mainly due to their high strength to weight ratio which will lead to lighter structures and fuel saving. Increased usage of thermosets, the main composite used in aerospace, raises new concerns about their end of life and environmental impact associated with long time-consuming and high cost intensive processes. For example, thermoset fuselage skins are mainly produced by gantry-mounted advanced fibre placement (AFP) machines and co-curing of stringers in a subsequent autoclave cycle. This increase the high cost already enhance by the production of carbon fibre material. To be able to compete with metal based, an alternative production process for structural parts of aircrafts could be demonstrated using the advantages of thermoplastics. Composite thermoplastic materials provide an interesting alternative to thermoset composite materials. They are thus adequate candidates against the current issues of relief and sustainable development especially in the field of transportation, energy, and construction.
MAYA project main objective is to develop innovative manufacturing routes integrating standard thermoplastic processes (injection moulding and thermoforming) combined with additive manufacturing to realize lining panels of fuselage to decrease the production time, reduce weight, optimize costs and enhance the part performances using thermoplastic materials. The high productivity rate of thermoplastic injection moulding associated to the design freedom of 3D printing will lead to an overall enhancement of the panels performances and manufacturing. MAYA will have direct impact on European aerospace industries through achieving its goals. The actives have been carefully planned in seven work packages in duration of 24 months to ensure that maximum impact in terms of manufacturing and assembly cost and time, environmental carbon foot print, etc will be delivered to European aerospace industries.