Caelestis

The European CAELESTIS project, coordinated by AIMEN Technology Centre, has developed a hyperconnected simulation ecosystem and predictive technologies to transform the design and manufacturing of aerospace structures. Aligned with the objectives of the European Green Deal, the initiative has helped pave the way towards more efficient and sustainable aviation through the application of digital solutions and innovative manufacturing processes.

The project has combined advanced simulation technologies, predictive tools and smart manufacturing processes to optimise the development of aeronautical components. These advances have culminated in a full-scale demonstrator, enabling the validation of the technologies developed and demonstrating their potential to reduce structural weight and improve quality.

In addition to coordinating the European consortium, AIMEN has led the development and optimisation of the manufacturing process for a composite aeronautical OGV (Outlet Guide Vane) demonstrator. This essential aircraft engine component directs airflow, contributes to engine efficiency and provides structural support between the engine and the aircraft.

Its development has combined automated dry carbon fibre lay-up technologies with epoxy resin transfer moulding (RTM). These processes have incorporated a real-time quality control system designed to detect and prevent defects during manufacturing and improve the reliability of the resulting components.

The validation results have demonstrated the potential of these technologies: the new OGV components achieve an approximate 35% reduction in weight and a reduction of up to 80% in manufacturing defects. These advances open up new opportunities to develop lighter, more efficient aeronautical structures, with the potential to help reduce fuel consumption and emissions associated with flight.

Developed under the European Union’s Horizon Europe programme, the initiative has brought together companies, universities and research centres from several European countries. With a budget of nearly six million euros, CAELESTIS strengthens international collaboration in digital technologies and advanced manufacturing, contributing to the development of a more competitive and sustainable aerospace industry.