Boosting the digital transformation
of aviation supply chains
for advanced composite aerostructures

CompSTLar is a Horizon Europe project focused on advancing the design, manufacturing, maintenance, and recycling of high-performance composite aerostructures for nextgeneration aircraft. By integrating physical and digital technologies, it enhances the entire lifecycle of aerostructures, reducing costs, improving sustainability, and supporting Europe’s leadership in low-emission, high-efficiency aviation.

Core Objectives

Zero-Defect Manufacturing

Develop advanced processes to ensure defect-free high-volume automated tape-laying (ATL) manufacturing for multifuncional and multimaterial (M&M) composite aerostructures.

Digital Twin-Driven Maintenance

Create a highly integrated digital twinbased framework for Structural Health Monitoring (SHM) and predictive maintenance across the full lifecycle of composite aerostructures.

Sustainable Repair and Recycling

Design digitally-assisted repair processes and circular economy strategies for the recycling of M&M thermoplastic composite structures, ensuring costeffectiveness and resource recovery.

Cross-value chain interoperability

Develop a modular digital pipeline to implement and improve a continuous data flow throughout the aircraft supply chain, supporting smarter design, manufacturing, and maintenance decisions.

Enabling Future Aircraft Configurations

Support the development of new aircraft designs and propulsion concepts with optimized, low emission composite aerostructures that enhance aerodynamic performance and fuel efficiency.

Expected outcomes

Advanced Composite Technologies

Development of high-performance thermoplastic composite (TPC) aerostructures, combining integrated inspection, non-toxic and recyclable materials, and new manufacturing routes such as in-situ consolidated automated tape laying (ISCATL).

Structural Health Monitoring & Repair

Creation of a digital twin-based Structural Health Monitoring and Assessment (SHM&A) framework to enable predictive maintenance and support costcompetitive, digitally assisted repairs.

Recycling & Circular Strategies

Sustainable end-of-life (EoL) approaches for TPCs, including reuse of recovered materials in high-volume manufacturing, enhancing circularity and reducing waste.

Interoperable Digital Pipeline

A modular digital infrastructure fostering connectivity and collaboration along the aviation supply chain, enabling data-driven lifecycle management of composite aerostructures.