HELIOS

HELIOS is developing new approaches for lightweight, high-rate capable CFRP fuselage shells with a strong focus on rivet-free structural joining. The project brings together industrial and research partners to investigate novel design principles, manufacturing technologies, and validation methods for future aircraft structures.

SWMS contributes its expertise in digital manufacturing and CAM software to support the practical implementation of these new concepts. Based on CAESA, SWMS is developing digital process models, new AFP/ATL layup strategies and programming approaches for bonded assembly processes, helping to connect design, simulation, and manufacturing more efficiently.

Future aircraft structures must become lighter, more efficient and easier to manufacture at industrial scale. Conventional riveted joining methods do not fully exploit the lightweight potential of CFRP structures and often increase process effort, manufacturing complexity and overall system weight.

At the same time, new structural concepts can only succeed if they are supported by reliable digital process planning, validated manufacturing strategies and robust interfaces between design, analysis, and production. This is exactly where SWMS sees a key need for action within HELIOS.

Within HELIOS, SWMS is extending its CAESA software platform to support advanced composite manufacturing strategies for future fuselage structures. This includes the integration of digital twins, new AFP layup methods such as Double-Double and Variable Angle Tow concepts, as well as interfaces for FEM export and design loops.

In addition, SWMS is developing process programming strategies for bonded longitudinal seams as part of a rivet-free shell integration approach. The goal is to create a more consistent digital workflow from engineering to manufacturing and to provide practical tools for evaluating and implementing new production concepts.

SWMS focuses on the digital manufacturing side of HELIOS. The work includes the development of new CAM functions, the integration of external algorithms via open interfaces and the generation of process programs for representative demonstrator parts. In this way, SWMS helps translate innovative structural concepts into executable manufacturing processes.

A central objective is to establish a closed digital loop between design, simulation, and production. This allows manufacturing results and planning data to be fed back into the engineering process and supports a more efficient and scalable development of future composite fuselage structures.