Thermoplastic sandwich structures for aircraft rudders

Special process allows rework-free sandwich forming

The sandwich panels were further processed using the Thermoplastic Sandwich Molding Technology (TSM) developed at the IMWS. This process makes it possible to form thermoplastic sandwich structures in a one-step process with simultaneous targeted production of functionally relevant areas. In contrast to conventional production methods, which require several process steps and manual post-processing, TSM is characterized by largely automated processing with short cycle times, as the researchers note. The thermoplastic sandwich material is heated above the melting temperature of the CFRP matrix and then thermoformed according to the component contour. In the load-bearing areas, the PEI honeycomb core remains structurally intact so that the sandwich retains its good rigidity and load-bearing capacity. However, the honeycomb core can be selectively melted in defined edge and connection areas. This allows for the integration of ramps, edge reinforcements or more solid zones for subsequent joining and fastening points - an essential prerequisite for use in complex aerospace structures, such as rudder shells.

Prototype proves suitability for use of thermoplastic sandwiches

A prototype segment of a rudder produced as part of "EcoRudder" demonstrates the potential of the rudder alternative made of thermoplastic CFRP sandwich, as emphasized. The demonstrator has sandwich shells that are integrated together with a segment of an original load-bearing spar made of CFRP to form a 1.5 meter high section of the rudder. Because future aircraft programs also require materials that can combine lightweight construction, sustainability and industrial manufacturability, the project has laid important technological foundations for this. The rudder segment was also tested under realistic operating conditions for both bending and torsional stress using a special multi-axial testing device in the DTU Structural Lab. The failure mechanisms of the thermoplastic rudder materials were also thoroughly investigated as part of an associated doctoral project at DTU, with the resistance to impact damage also receiving an obviously positive assessment.

(The results of the research project and the demonstrator will be presented at the JEC Composites Show from March 10 to 12, 2026 at the Econcore (stand 6P108) and IMWS (stand 5L142) stands. A detailed technical exchange on novel composite sandwich technologies will then take place on May 5 and 6, 2026 at the Composite Sandwich Conference in Halle).

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Date: 08.12.2025

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