Premium AEROTEC have developed and manufactured a wing spar with a sinewave-shaped web from carbon fibre composites, demonstrating a possible application of carbon fibre composite materials in the wing construction.
The component has been the result of a two-year technology project in collaboration with Boeing. Throughout the project Premium AEROTEC have been responsible for analysing, designing, and manufacturing the demonstrator.
The demonstrator represents a 2.5 metre-long section of a heavily loaded wing spar on a 1:1 scale. The web’s sinewaved-shaped form allows for a significant reduction in the weight of the component compared to standard spars today which have monolithic or discretely reinforced even webs.
Manufacturing the sinewave spar as one monolithic component using the patented Vacuum Assisted Process with just one single infusion cycle, allows to reinforce the junction area between flange and caps with endless CFC fibres. Since no discrete connecting elements such as bolts, doublers or bonds are used, the construction method enables additional weight savings (around ten percent according to Premium AEROTEC’s assessment) compared to other manufacturing concepts for sinewave spars.
In addition to the increased weight reduction for such a sizeable structural component, the number of components and the process and assembly steps could also be reduced considerably. This offers considerable advantages in respect of manufacturing and maintenance costs. The demonstrator shows that the decisive geometric and strength-relevant features for use in commercial aircraft can be fulfilled with the Vacuum assisted method at high reproducibility.