Novel high-performance hybrid thermoplastic prepreg material for aerospace applications

With the aim to take the use of composite materials to the next level, NHYTE developed innovative results, ranging from a novel recyclable hybrid thermoplastic composite material with multifunctional capabilities for aerospace applications. to new, efficient manufacturing concepts and methodologies for greener, integrated aero-structures. The proposed high-performing hybrid material offers improvements in terms of structural efficiency and weight reduction, which consequently results in an aircraft’s reduced fuel consumption and CO2, NOx emissions.

The hybrid material is based on amorphous bonding concept, in particular, the novel layer is composed of an APC-2 PEEK-carbon composite material, with the addition of external unreinforced amorphous polyetherimide (PEI) layers and it is suitable to be processed by the In-situ Consolidation Automated Fiber Placement (ISC AFP) method. It was designed and manufactured by a unique advanced automated prototype equipment and exhibits impressive advantages.

 

 

 

 

 

 

The novel hybrid thermoplastic material was manufactured with the innovative Prototype Equipment and afterward the spools were converted into slit tape format that would be compatible with the Automated Fiber Placement Method (AFPM). Physical-mechanical and virtual tests of the hybrid composite material were performed over the course of the NHYTE project. The figure below presents the first sample of the produced consolidated hybrid material.

 

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This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 723309.