Bio-based hybrid cabin door of ultralight helicopter with variable-axis fiber design

Abstract This paper presents the development of an integrated technology concept for the production of semi-structural fiber composite aerospace components with a bio-based hybrid laminate structure. In this context, the high lightweight potential of a variable-axial hybrid fiber-reinforced laminates compared to a multiaxial laminate design is of particular importance. As a demonstrator, a double-shell cabin door based on the cabin door of the ultra-light helicopter CoAx 2D of EDM Aerotec GmbH was redesigned in hybrid bio-based mixed composite construction using selected finite-element method (FEM) simulation and optimization tools, manufactured and characterized. The obtained results illustrate that compared to the reference carbon fiber-reinforced polymer (CFRP) component, the developed bio-based hybrid composite with local tailored fiber placement (TFP) reinforcement has a 30% biomass content, exhibits comparable mechanical properties and significantly contributes to increase energy and resource efficiency significantly.