Lufthansa Technik develops process for safe cabin installations in CFC aircraft

In the framework of the “Fiber Force” research project, started in
2010, working together with the German Aerospace Center (DLR) and the
Technical University of Darmstadt, Lufthansa Technik has developed
methods for load transmission into carbon fiber composites (CFC)
aircraft fuselage structures for VIP customer aircraft.

New generations of aircraft, such as the Airbus A350 and the Boeing
787, are manufactured predominantly out of CFC. As these aircraft
will also play an increasingly important role for VIP customers in
the future, appropriate changes to the original aircraft structure
are essential for manufacturer-independent modifications and
individual cabin solutions. It must be made possible to install
specific cabin components at the desired location in an aircraft, and
the primary structure must be reinforced in such a way that the
additional load can be introduced and distributed safely.

Within the project, funded by the Federal Ministry of Economics and
Technology (BMWI), it has now been possible to define the maximal
load on the floor panels for the first time, and to develop highly
efficient connectors, known as “floorpanel hardpoints”. These
components, comparable to inserts, are small enough to fit into the
palm of the hand and can be individually fitted to the cabin floor by
gluing them to the floorpanels. They facilitate the flexible fixing
of special cabin fittings such as cupboards, tables and partition
walls in the aircraft cabin with a maximal load of up to 3,000
newtons.

“The results of the “Fiber Force” research project
and the resultant force transmission concepts help us decisively in
the VIP Completion business to continue successfully meeting the
challenges of installing cabin interiors in the new composite fiber
aircraft designs," said Dr. Hans Schmitz, Senior Vice President VIP &
Executive Jet Solutions.

The results of the research project and the know-how acquired are
already being used in current Lufthansa Technik completion projects.
A total of 40 of the newly developed “floorpanel hardpoints” are
currently being installed in a Boeing 747-8.

The complete study and especially the execution of test series were
significantly assisted by a virtual R&D simulation.

In further subprojects, amongst other things, Lufthansa Technik has
been investigating ways to compensate for a sudden drop of pressure
in a VIP cabin, which often consists of many smaller rooms. Beyond
this, possibilities for load introduction in the side and upper
fuselage structure are being developed. The overall “Fiber Force”
project is due for completion by the end of November 2013.