Fri, 30 May, 2025
TWI is collaborating on an ESA-funded project for thermoplastic composite assemblies for the space sector.
TWI, in collaboration with the National Composites Centre (NCC), Airbus Defence and Space (Airbus DS), and Skyrora, is working on an ambitious project funded by the European Space Agency (ESA), aimed at advancing satellite and launcher structural design through the use of advanced thermoplastic composite materials and out-of-autoclave manufacturing processes. This joint effort targets a significant reduction in manufacturing costs and a boost in production efficiency amid the rapidly growing demand for high-performance, cost-effective satellite and launcher systems.
Traditionally, composite structures have relied on thermoset resin systems, valued for their strength and thermal stability. However, these systems present several limitations; they can be difficult to join and often lack the damage tolerance required for more dynamic applications. Thermoplastic composites offer a transformative solution. They provide high stiffness and strength, superior damage tolerance, reparability, and potential recyclability, while also being compatible with efficient, out-of-autoclave manufacturing methods.
The focus of this project is to qualify thermoplastic composite materials and joining techniques for space applications. The benchmark structure under evaluation includes carbon fibre-reinforced thermoplastic composite sandwich panels and cleats; components commonly used in spacecraft assemblies. The project specifically emphasises advanced joining technologies, excluding bolted or riveted joints, to enhance performance, manufacturability, and repair.
Key Objectives:
- Selection of materials and out-of-autoclave manufacturing processes
- Selection of a joining techniques compatible with space environments
- Manufacturing and testing of component-level samples under space-relevant conditions
- Full-scale demonstration of a structural assembly, validated through mechanical and thermal testing
- Development of a digital model to simulate performance and support future design optimisation
Beginning at Technology Readiness Level (TRL) 3, the project aims to reach TRL 6, with a full demonstration of the technology. The outcome of this initiative will deliver enabling composite technologies for both satellite and launcher applications, supporting efficient and sustainable space missions.