AE4ASM520 Industrial Composite Manufacturing

This course provides an in-depth understanding of composite manufacturing technologies for aerostructures at industrial scale, with particular emphasis on the challenges associated with automation and large component size. Building on the fundamental principles of composite manufacturing, the course examines practical industrial challenges related to material selection, mould design, vacuum setup, process-induced distortion, and the design and sizing of manufacturing systems for large structures. Students learn to identify manufacturing processes and associated pitfalls from the resulting components and tooling, and to assess the consequences of material and process choices in an industrial context. Particular attention is given to manufacturing performance indicators, including process robustness, energy and material consumption, equipment occupation time, non-operating costs, and flexibility. Manufacturing processes are also evaluated from a sustainability perspective by considering their consumption of energy, materials, and auxiliaries within the broader product life cycle. Teaching is based on interactive lectures and industrial case studies, complemented by exercises using Python scripts in Jupyter Notebooks to deepen understanding and encourage interactive exploration; no prior programming experience is required. The course is intended to include visits to the Center for Lightweight Production Technology at the German Aerospace Center (DLR) and the Airbus site in Stade, providing students with direct exposure to industrial-scale composite manufacturing.