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In the past five years in Andalusia
alone, the turnover of all these support
companies has nearly tripled.
One of the issues with carbon fiber
production is keeping costs down.
“Carbon fiber itself was very difficult to
obtain—there were few suppliers,” says
Jesús Marcos, director of Tecnalia Aerospace.
“It cost a great deal, and there were
very unique applications. Today, there are
more suppliers, and the challenge remains
the cost of production.”
SENER, an engineering technology
and consulting company, is developing
automated systems to lay down textiles,
reducing the manpower and therefore the
cost. Today, most of the work is still done
by hand. “Typically, the manufacturing
system has been very intensive and manual,”
says Rafael Quintana, director of
aerospace for SENER. “It’s like a big
fashion shop; there are literally hundreds
of people placing those composite textiles
into the molds and so on.”
EADS-CASA focuses on a similar
issue in carbon fiber production.
Through research on the best methods
for designing and producing curved and
complex carbon fiber airplane products,
scientists settled on the technique of
simple stitching. Employing people to
do the stitching would be prohibitively
expensive, however, so engineers created
industrial robots to do the handiwork—
at up to 100 stitches per minute.
After sheets are joined together, they’re
draped in alternate directions over a
mold and then pressed at very high heats
to harden.
SENER specializes in designing composite
material structures for aircraft.
Recently, the company worked with
SACESA
to create the belly fairing for the
Airbus 380—the lower section of the aircraft,
where the air conditioning and the
serving equipment are stored. “It’s a very
large structure to be made in a composite
material, and it demanded special techniques
for the design,” says Quintana.
Spanish companies are experts in the
production of carbon fiber reinforced
plastics, which replace metal parts in
airplanes to reduce weight and
increase efficiency.
photos courtesy of eads-casa
The Airbus 400M horizontal tail plane is constructed mainly
of carbon fiber composite material. (Shown at the EADS-CASA
production facilities in Tablada, Seville.)
“You need to lay different textiles in specific
positions in order for the fibers to
provide the strength and resistance for the
finest finished piece.”
The company designs parts requested
by large manufacturers such as Airbus.
“They make the overall systems design,
and specify the different components
they require in composites,” says
Quintana.
“We figure out a way to make
those parts.”
“Spain is one of the leaders in Europe
in terms of carbon fiber due to our
experience in the sector,” says Francisco
Mencía, administrator of Aeropolis,
an aerospace technology park i n
Andalusia.
Nanotechnology, a hot field for a
variety of boundary-pushing innovations
in science, has a place in the manufacture
of carbon fiber aircraft parts as well.
Nanoparticles added to synthetic material
can immensely increase the finished product’s
strength and resiliency. Nanoparticles
may also serve as a fire retardant, increasing
the material’s ability to withstand heat
and burning without generating toxic
gases. These technologies are in the early
stages, however, and still cost too much to
gain widespread use.
Tecnalia Aerospace is working with
carbon nanotubes, mixed with alloys of
other metals, to dissipate heat as efficiently
as possible. Another future application
of nanotechnology, perhaps more
suited to the world of science fiction in
the public’s eye, is the creation of invisible
aircraft. “It’s complicated,” says
Marcos of Tecnalia Aerospace, “but
basically these particles would absorb
some specific frequencies—radar, or
visual frequencies. So when the frequency
is absorbed, the aircraft would
become basically invisible.” He explains
the particles could be nano-sized or
slightly larger, but this technology is all
still under investigation.
Tecnalia Aerospace is also working
on a combination of advanced materials,
advanced heat dissipation, and flexible
electronics to create systems such as the
electronics box for aircraft. In their
　
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