Work

Robotic Sequential Ultrasonic Welding of Thermoplastic Composites: From Coupons to a Full-Scale Fuselage Demonstrator

Year: 2026

Type: article

Abstract: Multi-spot sequential ultrasonic welding is an interesting joining method for overlapping thermoplastic composite structures. In the framework of EU Clean Aviation Multi-functional Fuselage Demonstrator (MFFD) and the lower shell SmarT multifunctional and INteGrated TP fuselage (STUNNING) projects, SAM XL and TU Delft Aerospace Engineering collaboratively developed and demonstrated a robot-based sequential ultrasonic spot-welding process for the sub-assembly of structural frames and clips in a fuselage section demonstrator. This full-scale thermoplastic composite fuselage section demonstrator, recently awarded the 2025 JEC Innovation award, measures 8.0 meters in length and 4.0 meters in diameter. Our robot-based sequential ultrasonic spot-welding technology played a pivotal role in ensuring the joining of sub-components in the largest thermoplastic composite aircraft structure ever built so far. This paper provides a comprehensive overview of the technology development process and highlights the results achieved during the sub-assembly of the demonstrator as well as the challenges encountered.

Source: Processes

DOI: 10.3390/pr14030528

Authors: Abhas Choudhary, Ioan Bîrgăoanu-Acăei, Irene Fernandez Villegas

Institution: Delft University of Technology

Language: English

Topic: Advanced Welding Techniques Analysis

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Industry, innovation and infrastructure

Open Access status: gold

Estimated APC paid: $2,896