29 - January - 2026

The SAAT project has successfully completed the development and validation of an advanced ultrasonic welding (UT) process for thermoplastic composite (TPC) aerostructures, contributing to the development of key technologies for zero-emission aircraft. The project has overcome the current limitations of the state of the art, achieving reliable bonding of large thicknesses of up to 8 mm.

As part of the project, SOFITEC has manufactured multi-thickness test pieces of 4, 6 and 8 mm in PEEK and LM-PAEK materials by pressing, addressing the consolidation of high thicknesses for the first time. After analysing the parts and identifying defects, the test pieces were sent to AIMEN for evaluation as part of the experimental campaign.

AIMEN has carried out an exhaustive experimental campaign with more than 300 welding points and more than 100 parameter combinations, evaluating the effect of the material, the thickness of the top laminate and process parameters such as pressure, amplitude and speed. This work has made it possible to define the optimal welding configurations for each combination of material and thickness.

At the same time, collaboration with MECASONIC on the acoustic design of the welding system within SAAT solutions has enabled the development of a high-power source and a specific sonotrode for welding high thicknesses.

Furthermore, the collaboration with SYSPRO has enabled the development of a zero-defect manufacturing strategy, with AIMEN providing experimental data for training artificial intelligence models and integrating its real-time monitoring and analysis system into the welding facilities.

For its part, CTI has used the experimental results to improve the multiphysics simulation models of the process, integrating all the consortium’s interactions into an MBSE model.

As a final validation, a full-scale demonstrator consisting of a 1-metre-long piece of variable thickness, joined by two continuous ultrasonic welds, has been manufactured and welded, demonstrating the industrial viability of the technology developed.

Project title: ADVANCED WELDING PROCESS FOR MANUFACTURING THERMOPLASTIC COMPOSITE AEROSTRUCTURES

Acronym: SAAT

Project: EXP – 00171201 / MIG-20241007

Duration: from 03/09/2024 to 31/12/2025

Project budget: 1,769,750.00 €

Project grant awarded: 1,090,917.13 €

Project subsidised by the CDTI and supported by the Ministry of Science, Innovation and Universities.

Visit the project’s website here