A BAE Systems /UK EPSRC funded project Flaviir, is investigating the design and
manufacture of low cost carbon fibre composite airframe structures. Novel binder
coated unidirectional fibre tapes and tows were developed to enable the design
of optimised primary structures. The RTM technique was applied to mould net
shape sections of spar components. Various designs of wing attachment lugs were
manufactured with a range of reinforcement materials, including non crimp
fabric, novel binder coated tapes and conventional unidirectional prepreg.
Alongside these, a novel technique termed optimised tow lay up (OTL) was used to
reduce the weight. Binder coated carbon fibre tow is placed around the structure
in the principal stress directions to increase both bearing strength and overall
component stiffness. The novel materials, manufacturing technique and initial
element test results are presented
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