Aerospace structures must become lighter, more durable, and recyclable, enabling better aircraft performance and greater fuel efficiency. Innovation rarely happens by accident, and every technology needs a suitable demonstration platform.
In the CompSTLar project, the team is advancing a wide range of innovations — from multifunctional materials and novel structural design to manufacturing, repair, and recycling solutions that span the full composite lifecycle. The TRL 2–4 demonstrator must capture the essential challenges without excessive complexity.
Collins Aerospace: Driving Lightweight Structures
Within the CompSTLar project team, Collins Aerospace is leading efforts to evolve lighter-weight structures, developing aerostructure-specific multidisciplinary design optimization (MDO) approaches, and defining the TRL 2–4 demonstrator.
Our role is to ensure the demonstrator captures the key structural, manufacturing, and functional challenges essential for advancing next-generation composite technologies — without unnecessary complexity.
A Holistic Test of New Thermoplastic Composite (TPC) Capabilities
Engine cowling structures offer the ideal balance. Selecting one of these components presents all the structural, manufacturing, and functional challenges required for a meaningful demonstration, yet remains manageable within a reasonable timeframe.
These structures aren’t just simple panels — they combine:
- Large, singly- or doubly-curved skins
- Structural stiffeners
- Cut-outs (e.g., for access doors)
- Lightning-strike protection
- Tight surface quality tolerances
All these characteristics make these panels ideal for a demonstration vehicle. Designing and manufacturing one of these panels forces us to exercise virtually every critical process needed for large, complex aerostructures.
What We Aim to Achieve (and Deliver)
- Reduced weight and therefore improved fuel efficiency
- Faster, more efficient manufacturing
- Optimized performance and durability, not just novelty
Why the Engine Cowl?
Choosing an engine cowl as our demonstrator wasn’t about picking the simplest component — it was about picking the most representative, challenging, and rewarding part.
By doing so, we:
- Maximize learning
- De-risk the technology
- Deliver a demonstrator with real-world benefits: lighter structures, faster manufacturing, increased performance, and better durability
We believe this choice will help accelerate the adoption of thermoplastic composite technologies across the industry — enabling more efficient and competitive aircraft for the next generation.