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With the continuous growth of the aviation market, it is mandatory to have manufacturing processes that allow for cost reduction, high production rate and high performance structures enabling reduction of fuel consumption and CO2 emission. To that end, lots of out-of-autoclave technologies have been developed worldwide in the past years (RTM, VARTM, LRTM, VARI, RFI, etc) but only SQRTM (Same Qualified Resin Transfer Molding) enables to combine a good control of process key parameters (volume content, pressure, thickness, temperature) from closed mold capability and the use of high tough qualified prepregs. Starting the development of SQRTM in 2010, SONACA was the first European company to introduce SQRTM in serial production with the flaps of the Embraer E2 regional jets family. Since then, SONACA has pushed the technology further, combining it with automation, and has recently produced, first time right, a series of composite front & rear wing moveables with a very high level of structural and functional integration, achieving high cost reduction and performance. Comparing SQRTM to autoclave and RTM, the paper will demonstrate the gains achieved by SQRTM, combined with automation and integration, through the recent manufacturing of several full-scale wing moveables demonstrators, mechanical validations and economic analysis. [ABSTRACT FROM AUTHOR]

As part of the European Space Agency (ESA) Future Launchers Preparatory Programme (FLPP), SONACA (BELGIUM) and BRM (USA) companies joined their competences to develop a new concept of structural European launcher cryogenic upper inter-stage composite ring. This challenging program targeted the replacement of an ARIANE traditional aluminum ring by a lighter and affordable multi-functional composite structure. The ARIANE 5 aluminum specification was used as the basis of the design concepts, with adaptation to a future launcher 4.3 m diameter. After a preliminary design phase, involving selection of different manufacturing routes, material and processes by elementary tests made at coupon level, the 3D orthogonal weaving process was selected as the best candidate to realize a full scale ring demonstrator. The structure was designed, stressed and verified by test by SONACA, and the 3D weaving was optimized in close collaboration with BRM. Five 90° segment carbon fiber dry preforms were produced by BRM using the most advanced weaving automated technology. All these segments were injected by SONACA using their expertise in RTM process. The parts were controlled both geometrically and wrt internal defects by NDT. A 30° segment was successfully submitted to five static load cases up to failure, showing a TRL of 5. Four 90° segments were assembled by CFRP splices to exhibit a full ring demonstrator. [ABSTRACT FROM AUTHOR]