Following the delivery of the external wing demonstrator to Airbus Defense & Space, 2023 has seen the completion of technical activity on this major project led by Aciturri since 2016 within the framework of Clean Sky 2. This milestone has allowed the validation of TRL6 levels in flexible stand technologies developed at Aciturri, thermoplastic in-situ consolidation technologies developed by FIDAMC and integrated assembly infusion by Airbus Defence & Space.

In addition, validation activities have been completed on additive manufacturing supplementation techniques and manual drilling techniques using semi-automatic machines, which allow drilling and assembly in a single step. This made it possible to bring both developments to sufficient maturity for industrialization in a series of production projects.

The level of progress evidenced by Aciturri in this project has deserved the express recognition of the Project Officer in charge of monitoring the high-level Regional-IADP consortium where the EWIRA activity is framed.

DOMMINIO (from the Horizon 2020 framework program) will continue its activity in 2023, focusing on developing multidisciplinary optimization tools. This has allowed the development of specific applications for ongoing projects, resulting in a remarkable example of rapid implementation of innovative solutions to enhance value creation. Furthermore, thanks to Aciturri's contribution together with other DOMMINIO consortium partners, significant progress has been made in the manufacture of thermoplastic panels by in situ consolidation, stiffened with innovative geometries based on gyroids. AIMEN Technology Centre successfully manufactured a demonstrator of this architecture by the end of 2023.

Development activities have also continued on an innovative, in-line, contact-free inspection system for the early detection of manufacturing defects.

The project, funded by CDTI, has completed its third year in 2023 and the first elements of the final component, specifically the stiffeners with omega section, have been developed. The final demonstrator's first unit to be assembled has already been delivered. In addition, the development of the coating manufacturing process has continued, starting from a flat laminate obtained by AFP (Automated Fiber Placement) and its subsequent forming in a hot plate press. These first coatings have been subjected to NDT and micrographic tests to determine the quality of the resulting component. As with the Omega stiffeners, the first C-section beams have been produced using the same manufacturing process as the skins.

This year also saw the start of the conduction welding technology development. To develop this technology, both flat and bending radius specimens are used, which undergo the relevant mechanical tests to determine the level of stiffness achieved with this type of joint. In parallel to this development, the activities corresponding to induction brazing are being carried out; by generating magnetic fields, the components to be brazed reach the necessary temperature in the process, facilitating their joining. The development of both technologies will continue through 2024 and will be completed with the welding of the elemental parts produced in the previous activities.

The OVERLEAF project aims to develop a 95 kg liquid hydrogen tank by combining the development of new materials, such as composites and insulating materials.

As part of the Horizon Europe program's call to promote clean and competitive solutions for all transport means, Aciturri has been leading the OVERLEAF project since May 2022. The main objective is to develop a 95 kg liquid hydrogen tank, combining the development of new materials such as composites and insulating materials. 

The project started in May 2022 with generating tank specifications and requirements for the materials to be developed. In 2023, Aciturri reached its design maturity milestone called Preliminary Design Review, which was possible with the first versions of the developed materials and their characterization tests.

The OVERLEAF project aims to develop a 95 kg liquid hydrogen tank by combining the development of new materials, such as composites and insulating materials.

As part of the Horizon Europe program's call to promote clean and competitive solutions for all transport means, Aciturri has been leading the OVERLEAF project since May 2022. The main objective is to develop a 95 kg liquid hydrogen tank, combining the development of new materials such as composites and insulating materials. 

The project started in May 2022 with generating tank specifications and requirements for the materials to be developed. In 2023, Aciturri reached its design maturity milestone called Preliminary Design Review, which was possible with the first versions of the developed materials and their characterization tests.

The HALO stratospheric tourism project, which aims to commercially exploit flights to the stratosphere in a helium balloon-powered space capsule, continued to progress in 2023.

The primary activity during the year was improving the capsule descent system. This is done using a glider capable of guiding the element once the balloon flight has been completed and providing a smooth descent and landing. Aciturri sent a team to the California desert in the last part of the year to support this testing campaign, during which the established objectives were met. 

Further progress on stratospheric flight phases is planned for 2024. To this end, the company has already completed the manufacture of a second capsule for trials in 2024.

Within the framework of the 2022 call of the Aeronautical Technology Programme (PTA), Aciturri is leading the project ‘Innovative Aerostructures oriented to Emission Reduction (AIRE),’ in which the companies Airbus Defence & Space (ADS), Aeronautics, Engineering, Renewable Energies and Safety (AERYS), Titania Ensayos y Proyectos Industriales (TITANIA), M. Torres Innovación y Desarrollo (MTORRES), and Principia Ingenieros Consultores (PRINCIPIA) are all involved. The project aims to develop a thermoplastic aileron solution by researching new thermoplastic manufacturing technologies in line with the 2030 Sustainable Development Strategy.

2023 has seen progress in the activities for components made of heat-stable materials, for which a control surface lift was selected as a test component; the conclusions of the first manufacturing tests are already available, and the continuation of these tests is planned for the following year. Alongside this activity, work is being carried out on the challenges presented by high-thickness sandwich structures and aggressive ramps, and the first component manufacturing tests have been completed.

Optimization of the thermoplastic aileron structure has also been completed, and work has started on the specifications and first designs of the tooling to be manufactured. These tooling will be produced in 2024, and the first test of the elementary parts to be manufactured will be carried out.

LIDER aims to design new aerostructures for existing and future helicopters. Especially in terms of energy efficiency and decarbonization, aerodynamic improvements, environmental impact and circular economy, of course, while maintaining flight and operational capabilities and under a comprehensive approach that includes both the design of new elements, research into the use of new lightweight materials and the development of new manufacturing, assembly and mounting technologies to meet the latest specifications. 

Throughout 2023, Aciturri has been working on several areas of action, studying design concepts for a highly integrated composite aerofoil consisting of two automatically manufactured skins, one of which is stiffened with variable geometry omegas, and validating the process concept after analysis and manufacturability tests. Also, research has been carried out on the manufacturing processes of leading edges with heat-stable resin by infusion. Simultaneously, in collaboration with AIMPLAS, thermoplastic resins have been studied to improve their potential recyclability. In addition, after conducting the necessary test runs, the materials and process to manufacture the landing gear fairings (sandwich configuration with pre-impregnated out-of-autoclave cured materials) and the tail boom fairings (considering several types of resins and choosing the infusion process) have been designed and selected.

This project has been sponsored by the CDTI and supported by the Ministry of Science and Innovation through the Aeronautical Technology Programme (PTA) 's 2022 call.

In December 2022, as part of the Missions call, the CDTI approved ValorH2, a project that studies different stages of the hydrogen value chain (generation, compression, storage, transport and use of green hydrogen). The project partnership, led by Hiperbaric, also includes the industrial companies Aciturri, Adisseo, Ariema, Desmasa, DGH and MTorres, leaders in their respective fields. 

As part of the diversification strategy, 2023 continued to see the study of compressed hydrogen storage solutions for use in combination with fuel cells in transport elements or for large-scale storage. Aciturri aims to obtain 350 bar compressed hydrogen tanks type IV with different dimensions in the first phase, and during this year, the validation test run (rupture, leak tightness, damage tolerance and permeability) has mainly been completed, with only the filling test with H at 350 bar remaining to be carried out in the first quarter of 2024.

In addition, the design of a 4-meter demonstrator to be tested at 700 bar has been completed in 2023, identifying not only tank taping but also hydrogen management systems. Progress towards the end of development is expected to raise gravimetric efficiency above 7%. 

The Sherpa project, funded by CDTI in the framework of PID projects, consists of developing a medium-sized space launcher's fairing. Several innovative technologies have been studied and tested, such as a new concept for the opening mechanism (HRM) and rapid prototyping technologies to speed up validation processes, including the infusion of large parts and assembly using modular stands.

Manufacturing of the full-scale test prototype was completed in 2023, and various tests were subsequently conducted to verify that the calculation methods and kinematic simulations correlate with the opening tests at Aciturri's Ircio facility. The project concluded with the completion of the said opening test, during which it was demonstrated that the technical objectives had been met, as the fairing opens as specified by the potential customers, thus allowing the release of the payload from the launcher safely and securely, therefore contributing to the success of the mission.

The company launched the DOMAIN project as part of our strategy for aeronautical sector diversification: “Design and development of complex geometries in aeronautical multifunctional materials integrated into regional segments and business jets.” This project focuses on developing a range of highly standardized products that enable us to compete by creating scale economies and centers of excellence for manufacturing valid components for all segments. 

The detailed design phase was completed in 2023 to meet the requirements. Feedback started with the results of the manufacturability tests conducted and certification of the process standards for sandwich and monolithic structures.