[home] [Personal Program] [Help]

---

Session: Session 10: Defect Prediction and Mitigation in AFP
Session starts: Thursday 16 April, 13:10
Presentation starts: 14:10
Room: Main

---

Thomas Zenker (MT Aerospace AG, Franz-Josef-Strauß-Straße 5, 86153 Augsburg, Germany )
Andreas Uhl (MT Aerospace AG, Franz-Josef-Strauß-Straße 5, 86153 Augsburg, Germany )
Nicola Riva (OHB System AG, Universitätsallee 27-29, Bremen, Germany)
Celalettin Yumus (OHB System AG, Universitätsallee 27-29, Bremen, Germany)
Luca Marinangeli (OHB System AG, Universitätsallee 27-29, Bremen, Germany)

Abstract:
Over the past years, MT Aerospace (MTA) has significantly advanced its expertise in the Automated Fibre Placement (AFP) manufacturing process, expanding the range of composite structures and tanks that can be manufactured using this technology. As the technological capabilities as well as the associated design knowledge have matured, MT Aerospace has leveraged AFP not only for next-generation launcher applications like a carbon-fiber-reinforced polymer (CFRP) Upper Stage for Ariane 6 and future launchers, but also for realizing substantial benefits for satellite structures including central tubes. The technology opens possibilities in terms of potential shapes to be realized in primary and secondary satellite structures. So, traditional co-bonded sandwich designs with little design freedom can be challenged by complex shapes tailored to the requirements. One of the focussed parts is the Launcher Interface Frame (LIF) for ESA’s HARMONY mission, in which a CFRP frame represents the main interface towards the launcher. The HARMONY mission, which OHB System is the Prime contractor for, foresees a dual launch of two spacecrafts (see Figure 1), relying on a bottom dispenser provided by the launcher authority which replaces the Vampire 1194 off-the-shelf-adapter [1]. As illustrated in Figure 2, the primary load path in the lower section of the spacecraft transitions from the structural panels (depicted as transparent), which define the characteristic trapezoidal geometry of the spacecraft, to the dual-launch adapter (highlighted in green) through four Hold-Down and Release Mechanisms (HDRMs). Furthermore, the propellant tank is accommodated within the same lower section and is structurally supported by four bipods, ensuring stable load transfer during launch and in-orbit operations. To fully leverage the advantages of complex design solutions, an integrative approach is essential to ensure that manufacturing information such as local fiber orientations is consistently incorporated into the sizing and justification process. Alongside, the influence of geometrical design parameters on the manufacturability was simulated. A full-scale manufacturing breadboard (MBB) was built and evaluated to demonstrate the manufacturing process and thereby conclude PDR phase. An integral manufacturing of the sandwich structure and both AFP-laid skins was followed by a one-shot autoclave curing process. Layup behaviour of the geometrically challenging sections was studied in detail. Where needed, improvement actions were derived and verified. Following the successful completion of the Manufacturing Breadboard (MBB), a Structural Model (SM) is under development for static structural testing, planned to be carried out by MT Aerospace (MTA) in Q1 2026 to validate the mechanical performance of the primary load path. After completion of this phase, two Flight Models (FMs) will be manufactured and assembled together with all secondary structures, including brackets and sidewall panels.