CESPERT

Within the CESPERT project, innovative thermoplastic composites and related production processes have been developed for the creation of prototype elements in the transportation sector. The construction of composite systems involved the development of computational models and experimental testing.
In the Aeronautics sector, an emergency door for an ATR42 regional aircraft was built:
The window frame and structural components of the door were made of polyphenylene sulfide (PPS) reinforced with carbon fibers using a thermoforming process;
the skins were made of polyetheretherketone (PEEK) and carbon fibers using fiber placement technology and subsequently formed in an autoclave.

The assembled prototype meets aerospace requirements in terms of impact resistance and shows a 39% weight reduction compared to the traditional aluminum solution.
Furthermore, for the aeronautical sector, induction and resistance welding processes were studied to bond the stiffeners to the skins.
In the automotive sector, a tailgate was created using a thermoplastic composite of carbon fiber-reinforced polyamide (PA). The tailgate meets automotive torsional strength requirements and also achieves a 30% weight reduction compared to the steel solution and a 20% cost reduction compared to the thermosetting prepreg solution.
In the Railway sector, a bumper and a side panel for a lightweight tram were manufactured using thermoplastic composite and thermoforming processes.
The panel, made of glass fibers and polyetherimide (PEI), meets fire resistance requirements while also achieving a 48% weight reduction compared to the conventional aluminum solution.
The bumper, made of glass fibers and PPS, was designed to improve pedestrian safety while driving and achieves a 34% weight reduction compared to the aluminum solution.