Cost and weight analysis of ultra thick laminates for compact landing gear fitting

A typical metallic main landing gear fitting was designed and manufactured in carbon fibre reinforced polymer (CFRP). The component features wall thicknesses of up to 90 mm due to massive loads and compact dimensions. The aim was to reduce the weight and to provide a distinct cost benefit. Two prototypes of the fitting were produced. Based on the gained manufacturing experience the cost benefit was evaluated for a possible serial production. A new open mould manufacturing process was chosen in order to maximise flexibility and to reduce development costs. The entire manufacturing process was continuously optimised and refined. The gained experience was implemented and combined in a final study of a serial production of the CFRP fitting. In the last step the gained data were compared to the standard metallic fitting. For this example, ultra thick laminates (UTLs) provide a significant cost and weight benefit. The composite design can be categorised as highly manufacturing driven.