“FUSINBUL, “FUll Scale INnovative pressure BULkheads for regional aircraft fuselage barrel onground demonstrators”, is vital in order to perform the full barrel demonstrator tests, needed to validate the new concept of fuselage created and manufactured in the Green Regional Aircraft context.

This project aims to develop and validate two advanced manufacturing processes to reach a significant reduction in the overall production costs and flows for composite pressure bulkheads oriented to regional aircraft light-weight fuselage manufacturing. A final trade- off analysis will be drawn as well, including costs, advantages, implementation convenience, comparison with former costs and frame.

Bulkheads allow airtightness in aircraft fuselages, thus, the innovations and advantages achieved in FUSINBUL are potentially usable in future aircraft manufacturing.

Innovative low cost and low weight technologies shall be integrated into the fuselage structural demonstrator to get weight reduction, less manufacturing recurring costs, maintenance improvement, better fatigue and corrosion performance and implementation of new eco-compatible materials and processes. And the final step to enter them into use is validation through a test that needs 2 bulkheads as vital elements to close the fuselage cylinder.

The bulkheads will be manufactured using carbon fiber reinforced plastic (CFRP) and the most advanced techniques of layup. Two different technologies are going to be use for the bulkheads manufacturing:

  • Prepreg technology: using a cobonding manufacturing process (cured omega stringers cobonded to a fresh skin layed-up by Automatic Fiber Placement).
  • Infusion technology: using an unidirectional dry fiber material. Cured omega stringers and cured skin (layed-up by Automatic Fiber Placement) are infused by separate and then joint by rivets.

The light-weight properties of the carbon fiber will ease the tooling needed for the set-up of the fuselage test, since the lighter big components are the easier to handle them and the safer for human operation.  The manufacturing process will be optimized, in order to minimize the needed tooling and therefore make the most of the available resources.”

TOPIC LEADER: Leonardo Aircrafts