The new space race is driving the development of more efficient vehicles, lighter satellites and structures capable of withstanding extreme conditions without compromising their performance. Against this backdrop, thermoset composites have established themselves as one of the most important technologies for the design and manufacture of high-performance aerospace components.
At FIDAMC, the development of solutions based on thermoset materials forms part of a strategy aimed at addressing the challenges facing the aerospace industry through research, engineering and the advanced manufacture of composite structures.
Why are thermoset materials so important in the aerospace sector?
Every kilogramme saved on a launch vehicle, satellite or aerospace structure has a direct impact on the efficiency of the mission. For this reason, the sector has for decades been focusing on materials capable of offering high mechanical strength whilst being as light as possible.
Thermoset composites stand out precisely because of this combination of properties. Their excellent structural performance, dimensional stability and ability to withstand high loads make them an ideal solution for applications where safety and reliability are essential.
Furthermore, they enable the manufacture of components with complex geometries whilst maintaining mechanical performance far superior to that of many traditional materials.
Engineering and manufacturing for complex spatial structures
One of the major challenges facing the aerospace sector is the manufacture of structures which, as well as being lightweight, feature complex geometries and have very stringent precision requirements.
In this field, FIDAMC is working on the development of advanced processes to manufacture components such as structural adaptors, satellite dispensers and space launch vehicle components, where process engineering is just as important as the design of the part itself.
During the development of these projects, the combination of thermoset materials and automated manufacturing technologies enables the optimisation of both structural performance and the efficiency of the production process.
The centre’s expertise in the manufacture of complex monolithic structures is one of the key factors that sets it apart when tackling this type of development.
From material design to the manufacturing process
Choosing a material is not the end of the road; it is the starting point.
Each component requires an analysis of aspects such as behaviour under mechanical loads, stability during the manufacturing process, curing cycles, energy consumption, weight optimisation and the feasibility of its production.
Indeed, one of FIDAMC’s areas of work involves evaluating and optimising manufacturing processes for components traditionally produced from metal or other materials, analysing when a thermosetting composite offers advantages from a structural, production and energy efficiency perspective.
Advanced manufacturing to meet the new challenges of space exploration
Developments in the space sector are driving up demand for increasingly complex components with ever-stricter quality requirements.
To meet these needs, FIDAMC utilises advanced manufacturing technologies such as Automated Fibre Placement (AFP) and the Automated Tape Lay-up (ATL), which enable the production of large-scale structures with high levels of precision and repeatability. These capabilities are complemented by manual and automated lamination processes, as well as consolidation, shaping and curing using autoclaves, presses or ovens, adapting the technology to the component and the requirements of each project.
This approach is particularly relevant in space applications where geometric complexity and structural optimisation are key factors.
Innovating today to build the space of tomorrow
The aerospace industry is moving towards increasingly ambitious programmes, where innovation in materials must be accompanied by industrial processes capable of guaranteeing quality, repeatability and efficiency.
In this context, FIDAMC develops solutions ranging from research into new materials to the validation of processes and the manufacture of full-scale demonstrators, helping to reduce technological risks and accelerate the introduction of new solutions into the industry.
The aim is clear: to transform knowledge into industrial capability and to continue driving the development of composite materials that will enable the construction of a new generation of aerospace structures that are lighter, more efficient and ready to meet the challenges of the future.
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