New end-to-end digital framework for optimized manufacturing and maintenance of next generation aircraft composite structures

Informacje na temat projektu

GENEX

Identyfikator umowy o grant: 101056822

DOI

10.3030/101056822

Projekt został zamknięty

Data podpisania przez KE 10 Maja 2022

Data rozpoczęcia 1 Września 2022

Data zakończenia 28 Lutego 2026

Finansowanie w ramach

• Climate, Energy and Mobility

Koszt całkowity

€ 5 691 451,75

Wkład UE

€ 5 691 451,00

Koordynowany przez

INSTITUTO TECNOLOGICO DE ARAGON
Spain

Periodic Reporting for period 3 - GENEX (New end-to-end digital framework for optimized manufacturing and maintenance of next generation aircraft composite structures)

Okres sprawozdawczy: 2025-03-01 do 2026-02-28

Podsumowanie kontekstu i ogólnych celów projektu

Global aviation accounts for approximately 2.1% of global CO2 emissions and, by 2050, are expected to be seven to ten times higher than in 1990 due to the increase in air-traffic. To achieve the EU environmental goals by 2050, drastic improvements over current existing aircraft configurations should be implemented in terms of energy efficiency, reduction of the environmental impact, or increase of passenger comfort and safety . In this context, the implementation of novel holistic and circular approaches, leveraging the potential of Artificial Intelligence (AI), Internet of Things (IIoT), digital twins (DT), and automate robotics solutions will offer the European aeronautics industry and the whole aviation ecosystem the opportunity to maintain their global competitiveness and leadership while moving forward towards climate neutrality.
Thus, in GENEX, the development of a novel holistic end-to-end DT-driven approach is proposed. The main goal is to provide a framework for managing data from all systems and tools for gaining knowledge from overall composite component lifecycle by the integration of (1) innovative in-line process monitoring systems for measuring the manufacturing quality, (2) optimized on-board and on-site sensors for structural health and usage monitoring and remaining useful life prediction, and (3) advanced digital-based tools and methods for improving maintenance and repairing.
By building the new DT framework, GENEX target to deliver digital and eco-efficient manufacturing technologies to ensure flawless entry into service of composite parts as well as to advance further health assessment and MRO processes to allow continuous airworthiness of European aircrafts.

Prace wykonane od początku projektu do końca okresu sprawozdawczego oraz najważniejsze dotychczasowe rezultaty

The GENEX project has developed an integrated ecosystem of advanced technologies to improve the manufacturing, monitoring, maintenance, and repair of composite aircraft structures, with a strong focus on digitalisation and sustainability.
In manufacturing, a “Manufacturing-for-Performance” strategy was validated using Automated Tape Laying (ATL) for both thermoset (3R resin) and thermoplastic (PEKK) materials. Embedded sensors (fiber optic and piezoelectric) were successfully integrated, enabling structural health monitoring from the production stage. Progress was made in material state control using THz spectroscopy and in multi-physics simulations to support future AI-driven optimisation. A key achievement is up to 70% energy savings through out-of-autoclave processes, although manufacturing costs remain higher than current benchmarks. All developments were validated in an integrated manufacturing cell.
In the area of Health and Usage Monitoring & Management (HUM&M), GENEX developed a multimodal approach combining sensor networks, wireless nodes, and advanced simulation and AI models capable of predicting delamination with up to 90% accuracy. Due to regulatory constraints, the focus shifted to on-ground inspection, still enabling condition-based maintenance. This approach is expected to reduce inspection costs, increase aircraft availability, and minimise downtime.
For repair, innovative digital tools were developed, including the Visual Assistance System (VAS), which combines 3D scanning and real-time projection to guide technicians, improving precision, traceability, and efficiency; portable LIBS for contamination detection and cleaning; hot bonding process digital twin for cost-effective repair planning and online process control; and Smart Patch Repair, with sensing and crack arresting features in bondlines, which requires further maturation. Altogether, these solutions show potential to reduce repair time by up to 30%.
Finally, a Digital Twin Framework was designed and implemented, enabling the creation and operation of digital twins connected to real data across the lifecycle. The system, along with the individual processes, was successfully validated through demonstrators. Overall, GENEX contributes to a more efficient, digital, and sustainable aviation industry.

Innowacyjność oraz oczekiwany potencjalny wpływ (w tym dotychczasowe znaczenie społeczno-gospodarcze i szersze implikacje społeczne projektu)

GENEX has delivered a comprehensive set of results across the full lifecycle of composite aerostructures, contributing to eco-efficient manufacturing, advanced health monitoring, optimised MRO processes, and digital twin integration.
Key results include the demonstration of ATL-based manufacturing using recyclable 3R resin and high-performance thermoplastics, supported by embedded sensing and multiphysics modelling for the degree of curing and crystallisation. Energy-efficient out-of-autoclave processes achieved up to 70% energy savings, while digital tools and simulations laid the foundation for AI-driven optimisation.
In parallel, GENEX developed a robust SHM framework combining reduced-order models and wireless ultrasonic sensing, enabling near real-time damage detection and supporting condition-based maintenance strategies.
In MRO, the project delivered innovative digital repair solutions such as the Visual Assistance System (VAS), portable LIBS contamination detection, and advanced hot bonding control, significantly improving repair accuracy, traceability, and efficiency. These technologies show strong potential to reduce downtime and operational costs while enhancing reliability. The Digital Twin Framework further integrates data across the lifecycle, enabling predictive maintenance and continuous airworthiness.
From an impact perspective, GENEX demonstrates potential environmental benefits of up to 20% reduction in lifecycle emissions, with long-term disruptive gains up to 30% by 2035. Economically, the shift to predictive maintenance and elimination of unscheduled repairs can significantly reduce lifecycle costs and increase aircraft availability. The project also strengthens European competitiveness by advancing digital, data-driven aviation technologies.
However, further uptake requires addressing key needs: increasing technology readiness through large-scale industrial demonstrations; advancing AI-based monitoring and THz sensing towards higher TRLs; ensuring access to investment for industrialisation; and supporting standardisation and certification frameworks, particularly for SHM and digital repair processes. Continued collaboration with industry, along with IPR management and internationalisation strategies, will be essential to accelerate commercialisation and adoption across aviation and other sectors.