Title: Ultra-High-Rate Manufacturing of Thermoplastic Aircraft Tip Rib using Hybrid Overmolding

Authors: Waruna Seneviratne, Jerome Teoh, John Tomblin

DOI:

Abstract: High-rate production of fatigue-critical aerospace structures remains constrained by long cycle times, high scrap rates, and labor-intensive subtractive manufacturing. This paper presents a fully automated hybrid manufacturing system for a complex thermoplastic tail tip rib used in an electrical vertical take-off and landing (eVTOL) aircraft. The system integrates thermoforming of continuous-fiber reinforced thermoplastic laminates with injection overmolding of short-fiber thermoplastic compounds. Using current production data for a metallic baseline component, the proposed approach reduces a conventional 80- to 100-hour machining process, during which approximately 80% of the starting material is removed, to an automated production cycle on the order of two minutes, while producing a monolithic, near-net-shape structure. A simulationdriven process development methodology was implemented to minimize trial-and-error. Thermoforming was analyzed using AniForm with laminate-aware shell formulations to identify near-net-shape blanks, predict deformation and defect formation, and evaluate mitigation strategies. Injection overmolding was analyzed using Moldex3D with a detailed runner–cavitymoldbase model to assess cavity filling behavior, gate strategy, and machine feasibility. Simulation results were correlated across process stages to establish preliminary process settings and promote robust interfacial bonding through controlled insert remelting. The manufacturing system integrates automated tape placement and ultrasonic tack welding, high-rate laminate consolidation, thermoforming, and injection overmolding. Aerospace-grade thermoplastic materials were employed, including a Victrex AE250 low-melt PAEK laminate reinforced with AS4 fibers and carbon-fiber-reinforced PEEK for overmolded features. Experimental validation demonstrates that the integrated process enables high-rate, low-waste production of lightweight, fatigue-critical aerospace structures with significant reductions in cost, energy consumption, and material waste.

References: 1. Seneviratne, W., Teoh, J., Herath, I., and Schubert, E., Ultra-high-rate Manufacturing of Thermoplastic Window Plug using Hybrid Overmolding, SAMPE Journal, 60(6), pp. 4554, 2024. 2. Victrex plc, AE250 LM-PAEK Technical Datasheet, 2023. 3. Victrex plc, PEEK 90HM40 Material Datasheet, 2023. 4. AniForm Engineering, AniForm User Manual, Enschede, Netherlands, 2024. 5. Moldex3D, Moldex3D R&D Simulation Theory Manual, Hsinchu, Taiwan, 2023. 6. Altair Engineering, HyperMesh Documentation, Troy, MI, 2023. 7. Dassault Systèmes, 3DEXPERIENCE Platform Documentation, Vélizy-Villacoublay, France, 2023.

Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 165

Pages: 15

Price: $30.00