Life Cycle Assessment and Costing of Thermoplastic Composite Aircraft Component with Digital-Assisted Repair Technologies
Authors/Creators
- 1. Innovation in Research and Engineering Solutions SNC (IRES), Brussels, Belgium
Description
The GENEX project is redefining aerospace sustainability through thermoplastic composite components and digital-assisted repair technologies. Addressing key industry challenges—high manufacturing costs, energy use, waste, and non-recyclable materials—GENEX introduces a holistic approach combining advanced manufacturing, integral health monitoring, and digitally assisted repair.
What’s new?
✅ Recyclable composites manufactured via AFP out-of-autoclave processes, reducing waste and energy consumption.
✅ Embedded sensors & digital twins for real-time structural health monitoring and predictive maintenance.
✅ Smart repair solutions with laser cleaning, scarfing assistance, and optimized heating control.
Impact at a glance:
🔹 Up to 37% reduction in Life Cycle Cost (LCC) in advanced scenarios—surpassing project targets.
🔹 Significant environmental gains, with cradle-to-gate impact reductions of up to 49% thanks to lower energy use and digitalization.
🔹 Major savings during use phase through reduced inspections and downtime.