Development of Multi-Material Overhead Stowage Systems for Commercial Aircrafts by Using New Design and Production Methods

Innovative, lightweight and cost-efficient aircraft components require the use of modern lightweight materials and efficient production technologies. A promising technology is the combination of chopped fiber Sheet Molding Compounds (SMC) and pre-impregnated, continuous fiber fabrics processed by single-stage compression molding. The so-called Hybrid SMC Technology obtains cost-efficiency as well as time-saving production of loaded and functional aircraft components. However, reliable design principles for components and computing methods for predicting the material behavior have to be developed for a use in aviation industry. Hence, this paper deals with the development of materials, fabrics, manufacturing processes and computing methods related to the Hybrid SMC Technology. Those developments are demonstrated and validated by the implementation of a lightweight multi-material overhead stowage compartment (OHSC) using new design approaches as well as assembly principles.