Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAMThe aviation industry is undergoing change: Innovation cycles are becoming shorter, and production and manufacturing requirements regarding cost-effectiveness, emissions, and environmental sustainability are increasing. To meet these challenges, the aircraft components of the future must be more cost-effective, flexible, and environmentally friendly. The Fraunhofer IFAM supports this transformation in the "MORPHO" project. The goal: a quieter, more efficient, sustainable, and economically viable aviation industry of tomorrow. Using an aircraft turbine blade as an example, our researchers have demonstrated the potential of integrated sensors.
The Future of Component Management: Continuous Monitoring with Innovative Sensor Technology
Today, almost all aircraft components can be made from fiber-reinforced plastics (FRP), which consist of resin reinforced with glass or carbon fibers. The use of FRP allows for the integration of sensors, such as fiber Bragg gratings (FBGs), already during the manufacturing process. Our research focuses on advanced manufacturing techniques such as Resin Transfer Molding (RTM), where the sensors are inserted into the closed mould via the preform. These sensors not only provide valuable data during manufacturing but also enable continuous monitoring of the component's condition throughout its service life.
Additionally, we are exploring innovative printing techniques such as screen printing, dispensing methods, and Aerosol Jet® Printing to apply sensors directly onto components. In the "MORPHO" project, we have successfully printed piezoelectric and temperature sensors onto fiber-reinforced components, enabling data collection for digitalization purposes or structural health monitoring.
Increasing Efficiency in Aircraft Maintenance Processes
By integrating sensor technology into aircraft components, we not only enhance safety and reliability but also significantly improve maintenance efficiency. In the future, contactless sensor structures could drastically reduce maintenance times and lower operational costs.
Fraunhofer IFAM offers the aviation industry a broad spectrum of innovations in material qualification and manufacturing processes. This contributes to a more sustainable, efficient, yet economically competitive aviation sector for the future.
