3 - Novembro - 2025

The objective of SAAT is to develop an advanced ultrasonic welding (UT) process for the manufacture of thermoplastic composite (TPC) aerostructures, thereby contributing to the development of zero-emission aircraft. The project seeks to overcome the current challenges of UT welding, enabling the reliable joining of large thicknesses (up to 8 mm) and variable thickness joints (between 3.5 and 8 mm), a disruptive leap forward from the current state of the art, which is limited to a constant thickness of 4 mm.

SAAT includes the development of design tools (MBSE) and multiphysics simulation of the welding process, a new flexible welding head that integrates real-time monitoring and control systems, and an online non-destructive testing (NDT) system based on vibrothermography. In addition, it will generate a digital decision support tool that will use advanced data analytics and artificial intelligence (AI) to correlate process parameters with joint quality and defect generation.

The SAAT consortium covers the entire value chain, from technology developers to end users (early adopters) where the solutions will be validated (SOFITEC). It is made up of four companies: CTI (leader, design and simulation engineering services), SOFITEC (TIER2 aerostructure manufacturer), MECASONIC (UT welding equipment developer), and SYSPRO (automation and digitalisation solutions provider).

The main results will be: CTI will offer engineering and simulation services (R1, R2); MECASONIC will market the flexible welding head (R3); SYSPRO will provide the decision support tool (R4) and the NDT inspection system (R5); and SOFITEC will validate a demonstrator (R6), positioning itself in the advanced manufacture of TPCs.

SAAT also involves the participation of AIMEN (Porriño, Pontevedra) as a subcontractor, a technology research centre specialising in the processing, digitisation and automation of composite materials. AIMEN plays a key role as a leading technology partner in the development of ultrasonic welding applied to composite materials. Having led previous European projects and contributed to the Multi-Functional Fuselage Demonstrator (MFFD), AIMEN brings solid experience in materials, advanced manufacturing processes and monitoring techniques, strengthening the position of the national and European industry in the development of the next generation of zero-emission aircraft. Within the framework of SAAT, AIMEN is responsible for the ultrasonic welding of a demonstrator, as well as the associated experimental campaign. In addition, it will carry out the upgrading of welding equipment to enable real-time monitoring and control of the process, including defect detection using advanced techniques such as vibrothermography.

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

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 €

Visit the project’s website here