Innovation Domains

Through a wide portfolio of collaborative R&D projects, Sonaca is actively developing and maturing innovative technologies that address the key challenges of future aviation.

Systems & Leading Edges

Improved ice protection system

The focus on ice protection systems is a key aspect of our research and technology strategy. As a global leader, we are primarily focused on two main areas:

Electrothermal ice protection systems (ETIPS). With a strong commitment to the future of more electric aircraft, we have been developing our own ETIPS for over a decade. We are now achieving a high level of maturity at TRL5. This technology is on track for commercialization in the near future.
Low power electric IPS. Minimizing power consumption is crucial, and our teams are working on innovative ice protection systems that utilize electro-mechanical properties. Early results show promising potential for this emerging technology.
Less bleed solutions : innovative solutions to reduce by 30% or more the bleed flow needs for conventional ice protection system technology (bleed air)
Continuous improvement of our homemade icing simulation software to better optimize the performance of the system

Leading edge of the future

As a global leader in wing leading edges and slats, Sonaca is committed to developing cutting-edge solutions for future aircraft wings.

With the demand for longer, thinner, and quieter aircraft wings on the rise, we are dedicated to creating slats that accommodate these requirements, such as higher wing deflections and noise reduction. These innovations will play a crucial role in reducing emissions in future aircrafts.

Engineering the Future of Leading Edges

Among the major developments ongoing :

The development of silent slats and slats for long and thin wings
The development of a low-power electromechanical ice protection system
The completion of our innovative Plug-and-Fly leading edge concept, enabling drastic reduction of installation time on the wing
Natural Laminar Flow Leading Edge bringing significant reduction in the aerodynamic drag

Hydrogen & Zero Emission Aviation

VITAL-LH2

Aciturri has coordinated the VITAL-LH2 project, which focuses on researching advanced technologies for the efficient and safe storage of liquid hydrogen, contributing to the technological challenges associated with the decarbonization of the aeronautical sector and the transition to sustainable energy systems. The project is being developed in collaboration with technology partners CellMat, Hiperbaric, and AMTEC, which contribute complementary capabilities in advanced materials, manufacturing processes, and new test development, respectively. Aciturri has led the development of the cryogenic tank demonstrator, which aims to mature innovative solutions for liquid hydrogen storage through the design, manufacture, integration, and experimental validation of a representative system. Aciturri has participated in the following main areas of the VITAL-LH2 project: Development of the cryogenic liquid hydrogen storage tank demonstrator: design, manufacturing, testing, and technical coordination of the consortium. Development of thermo-fluid simulation models to analyze the thermal behavior of the system and optimize its design. Research into advanced leak detection and structural monitoring solutions under cryogenic conditions. Collaboration in the technical-economic feasibility analysis and industrial scalability of the solutions developed. This project is subsidized by the Center for Technological Development and Innovation (CDTI), within the program to support Science and Innovation Missions.

THESA

Aciturri is participating in the development of the THESA project, “SUSTAINABLE HYDROGEN-ELECTRIC PROPULSION TECHNOLOGIES FOR NEXT-GENERATION AIRCRAFT, in english” which aims to develop zero-emission aircraft technologies and address the decarbonisation challenge in the aviation industry.

More specifically, Aciturri is leading the project to mature the technologies necessary for developing a hydrogen fuel cell-based power plant integrated into a test aircraft.

Within the THESA project, Aciturri has contributed in four areas:

Collaborating in the modification of the aircraft structure selected as a test bed.
Leading the development of the pressurized hydrogen tank and its integration into the aircraft.
Researching the application of additive manufacturing technologies with metallic materials in air intakes.
Collaborating in the research and development of composite material battery casings.

This project is funded by the Centre for Technological Development and Innovation (CDTI), under the Ministry of Science, Innovation and Universities, through the Misiones 2024 call for proposals.

H2ELIOS

This project, which addresses the challenge of developing a cryogenic tank for aviation, began in 2023. It also represents Aciturri's first role as leader and coordinator in a major project of the Clean Aviation public-private initiative (co-financed by the European Union).

The project is developing a liquid hydrogen tank demonstrator for aircraft that will make zero-carbon aviation viable, with minimal weight impact and safety standards equivalent to the current ones.

In addition to coordinating the H2ELIOS consortium, Aciturri is leading the design and engineering integration activities for the referred demonstrator, as well as the development of the manufacturing processes for the external tank and assembly of the complete demonstrator. 

Link to the project website: Home | H2ELIOS

NEWBORN

With important ties and synergies with the H2ELIOS project, Aciturri is also participating in the Clean Aviation (EU co-funded) NEWBORN project (led by Honeywell), which is developing a complete demonstrator, from the fuel tank to the propeller, for a fuel cell-based aircraft propulsion system.

This technology allows for a 100% reduction in polluting gases (only water is emitted). Aciturri is leading the work package for supplying hydrogen to fuel cells through a tank with highly integrated hydrogen management system components. 

Link to the project website: Newborn project

VALORH2

Aciturri participates in the development of the ValorH2 project "Research into new technologies, materials and processes associated with the hydrogen value chain", which includes, among other activities, the hydrogen generation by alkaline electrolysis technology, the compression of this gas at very high pressure and providing a high flow rate, innovative storage and transport solutions at very high pressure, and the use, on the one hand, of the hydrogen to refueling electric vehicles (fuel cells); and on the other hand, in a methanation process of CO2 recovered in the chemical industry (chemical reagent), with the aim of increasing efficiency, reducing the operative costs and minimizing the carbon footprint.

Aciturri leads the research of storage solutions for transport, distribution and service of hydrogen at high pressure. The storage solutions to be developed within the project are classified into type IV and type V tanks for mobile, stationary and intermodal transport solutions for hydrogen application for high pressures (700 bar) and large dimensions (5-11 m). It is estimated that progress at the end of the development will allow raising the gravimetric efficiency above 7%, by improving leakage, insulation and decreasing the H2 permeability of the liners.

This project is funded by the Center for Technological Development and Innovation (CDTI in spanish), under the Ministry of Science and Innovation, through the Missions 2022 call, which has “Next Generation EU” European funds within the Recovery and Resilience Mechanism.

OVERLEAF

The objective of the OVERLEAF project is to develop an innovative concept of liquid hydrogen tank for use in aviation without the need for high vacuum. Aciturri is leading this project which will reach TRL 3 level of technological maturity, being able to prove the validity of the concept of its proposed hydrogen tank. The need for this development is supported by the energy transition that the European Union wants to achieve through its "Hydrogen Roadmap Europe: A sustainable path for the European Energy Transition". The aeronautical sector sets the objective of reducing the effect of flights on global warming by between 50% and 90%. Hydrogen is the energy carrier that will make a significant contribution to meeting the targets.

The consortium, led by Aciturri Engineering, SLU and formed by AIMEN, CANOE, Universitat de Girona, Technische Universiteit Delft, Arkema France SA, ICSI, Norges Teknisk-Naturvitenskapelige Universitet and AIMPLAS, will address different challenges ranging from the description of the specifications of the tank and the development of new materials to the production of the prototype and testing to ensure its functionality.

OVERLEAF is an ambitious project supported by the experience of each of the participating companies, positioning the tank concept on which it is based as a potential candidate to be the hydrogen tank that will integrate the aircraft of the future.

Web OVERLEAF

This project is subsidized by the European Union through the 2021 call for Cluster 5 of the Horizon Europe Program.

Structures, Composites & Manufacturing Processes

Integrated composite parts

Sonaca has an extensive knowledge in SQRTM processes combined with ATL to get integrated composite parts. Sonaca has developed a one shot out of autoclave SQRTM processes from design to certification. While significantly reducing recurrent costs thanks to combination of both lay-up automation and assembly time decrease, this mature technology provides prominent weight savings and outstanding quality.

This technology is now ready for many opportunities: advanced air mobility, business jets but also commercial and regional aircraft. The development continues with more automation, application of the integration strategy to new components and materials.

TIANA

INDUSTRIAL TECHNOLOGIES FOR SUSTAINABLE AND COMPETITIVE AERONAUTICS (TIANA)

Airbus Operations SL leads the TIANA project in which ACITURRI, ACCIONA, MTORRES, TECNATOM and OBUU are participating.

The overall objective of the TIANA project is to address the research of disruptive solutions for aircraft structural components based on intelligent, automated and high rate manufacturing technologies and the use of new materials with improved functionalities which allow obtaining better integrated and lighter structures, contributing to a significant reduction in both aircraft consumption and weight, as well as recycling technologies that improve the carbon footprint and ensure the circular economy.

On the other hand, the project addresses the research of adaptive architectures for new zero-emission auxiliary power systems with H2.

This project also aims to ensure the sustainability of the manufacturing processes and of the aircraft itself, seeking to reduce the environmental impact through the reduction of energy consumption compared to current processes, the reduction of waste generated, the recycling/reuse of waste and the implementation of composite materials from renewable sources.

EXP 00159936 / PTAG-20231006

This project is funded by the Ministry of Science and Innovation and subsidized by the CDTI.

LIDER

Aciturri Engineering participates in the development of the Disruptive Helicopter of the Future - LIDER project, whose objective is the design of new aerostructures for current or future helicopters, whose standards are in line with the new global needs. Especially in terms of energy efficiency and decarbonization, aerodynamic improvements, environmental impact and circular economy, of course, without detriment to flight and operational capabilities, and under a comprehensive approach that includes both the design of new elements, research on the use of new lightweight materials and the development of new manufacturing, assembly and assembly technologies that meet the new specifications.

Aciturri will be in charge of the design, development and manufacturing of the Belly Fairing as well as the ALDI (Disruptive wing) Landing Fairings, using pre-preg materials out of the the autoclave. We will also design, develop and manufacture the CES fairing (Efficient and sustainable fairing), using infusion out of the autoclave.

This project has been sponsored by CDTI with file number PTAG-20221005 through the call for the year 2022 of the procedure for granting aid for Strategic Sectorial Business Innovation Initiatives ("Aeronautical Technology Program"), within the framework of the Recovery, Transformation and Resilience Plan (financed by Next Generation EU funds, including the Recovery and Resilience Mechanism) and the State Program to Catalyze Innovation and Business Leadership of the State Plan for Scientific and Technical Research and Innovation 2021-2023.

Visit the LIDER website

HERWINGT

Aciturri actively participates in the HerwingT project, which consists of a consortium of 28 companies, including prominent entities such as Airbus, Leonardo, Fokker, MTorres, FIDAMC, and universities from various European countries.

The activity focuses on designing an innovative wing for the future hybrid-electric aircraft that will contribute to the overall goal of reducing fossil fuel consumption, CO2 emissions, and other pollutant gas emissions.

Aciturri leads the integration of a technological demonstrator of a wing control surface with different high-integration technologies. This surface will develop dry fiber technology with the challenge of integrating the leading edge and structure into a single piece. Currently, the two most important milestones of the program, the PDR and the CDR, have been successfully passed. Additionally, the first manufacturability tests of integrated elements have been carried out, confirming the viability of the proposed manufacturing processes. In this same demonstrator, Aciturri collaborates with thermoplastic and welding technologies for one of the skins and the central spar, both made of this material.

Furthermore, Aciturri collaborates in the development of a new process for anti-erosion protection of the wing's leading edge and in the design and manufacture of the thermoplastic part of future regional aircraft leading edge.

NEOTAIL

Aciturri participates in the NEOTAIL project as one of the firms integrated in a consortium of companies. Aciturri is responsible for the work package for the development of a rudder for a medium-sized commercial aircraft. This will incorporate technological improvements that will allow higher production rates and lower costs, basing its construction on the use of thermoplastic resin materials reinforced with carbon fiber.

On the other hand, future aircraft will have to comply with new international regulations to reduce the environmental impact, both in their production and in their operating life, with the aim of minimizing emissions of polluting gases such as NOX and CO2. For this reason, the selection of thermoplastic arrays aims to contribute to the achievement of these objectives, since their easier recyclability allows components to be reused or removed from the production chain at the end of their useful life in a safer way.

This project will also address a change in the classic configuration of the rudders, seeking a greater integration of most of the elements of the torsion box in a single piece of CFRP with thermoplastic matrix. In this way, a multi-spar type caisson will be constructed, reinforcing the liners with stiffeners where necessary. This configuration eliminates transverse ribs, so the time and materials required for assembly are drastically reduced. For the installation of the invariant elements with respect to the most usual configuration (LERs, Skins, Fairings, Fittings...) improvements and optimizations of processes and tooling will be sought to reduce assembly times.

Within the NEOTAIL consortium, AIRBUS collaborates closely with Aciturri in the development of this work package, dedicated to control surfaces, as a possible end user. For the execution of the work, Aciturri is also supported by prestigious Technological Centers, such as FIDAMC in Getafe and CIDAUT in Boecillo.

This project has been subsidized by the CDTI and supported by the Ministry of Science and Innovation.

AERCOST, future components & systems

The objective of AERCOST is to obtain disruptive solutions in aerostructure components based on the use of new materials. The aim is to improve functionalities (fire and impact resistance), advance in manufacturing technologies that allow lighter designs, and therefore, aircraft with lower weight, higher efficiency and lower CO2 emissions to the atmosphere.

AERCOST will enable these components to be better integrated into zero-emission propulsion systems. It will deepen the automation of complex processes, which by their nature have until now been handcrafted, to ensure the evolution of procedures towards the digital environment.

The AERCOST project offers the market high value-added solutions to address the challenge of mitigating the environmental impact of air traffic, ensuring excellent performance and quality control of new designs.

The AERCOST consortium is composed of Aciturri Engineering, Airbus Operations, MTorres Diseños Industriales, IDEC Ingeniería y Desarrollos de Composites, as well as Troqueles y Moldes de Galicia.

This project has been subsidized by the CDTI and supported by the Ministry of Science and Innovation.

MULTIGLIDE

Aciturri participates in the Aeronautical Technology Program (PTA) for large companies of CDTI, as leader of the MULTIGLIDE project.

Its mission is to improve the aerodynamic efficiency of aeronautical aerostructures, so the activities are focused on two main lines of work.

To achieve lighter designs to reduce greenhouse gas emissions, and to improve production efficiency in order to reduce manufacturing times and costs.

The consortium formed by Aciturri Engineering SL, Sinergia Racing Group SL, and Applus+ Laboratories, have joined forces to meet these challenges through new concepts of integration of structures (Aciturri) with the "Glide" Forming process (Applus+) and the manufacture of more efficient and higher quality tools (Sinergia).

MULTIGLIDE will enable the participating companies to be trained in this type of solutions in order to gain competitiveness, by capacity and diversification, in new contracts for future aircraft that respond to these geometries.

This project is subsidized by the CDTI and supported by the Ministry of Science and Innovation.

AIRE - Aeroestructuras Innovadoras orientadas a la Reducción de Emisiones

ACITURRI participates in the development of the AIRE project, which aims to research a set of new sustainable technologies that lay the foundations of knowledge for future developments of elementary parts and the research of assemblies to reduce pollutant emissions both in their production processes and in the aircraft once in service. To this end, several lines of research will be addressed in different fields related to the area of aircraft structural engineering and factories of the future. All this will result in greater efficiency and a reduction in the volume of CO2 emitted into the atmosphere as a result of manufacturing and assembly activities in the sector and air traffic itself, so AIRE is a project aligned with the Sustainable Development Strategy 2030, based on responsible and sustainable production and consumption.

This project has been subsidized by the CDTI with file number PTAG-20221019 through the call for the year 2022 of the procedure for granting aid for Strategic Sectorial Business Innovation Initiatives ("Aeronautical Technology Program"), within the framework of the Recovery, Transformation and Resilience Plan (financed by Next Generation EU funds, including the Recovery and Resilience Mechanism) and the State Program to Catalyze Innovation and Business Leadership of the State Plan for Scientific and Technical Research and Innovation 2021-2023.

COMP_COAT

Aciturri participates in the development of the COMP_COAT project, an R&D project in effective collaboration between technology centres and companies in Castilla y León, together with the CTME Foundation and the CIDAUT Foundation, and the companies MPB Aerospace and Imatec.

The aim of the project is to research new coatings on composites and technical plastics with specific functionalities for the transport and biomedical sectors. In the project, Aciturri aims to study the improvement of the properties of certain composite materials, against temperature and against wear and erosion, through the application of thermal projection technology on the surface of these materials.

The project is funded by the European Regional Development Fund (FEDER) of the European Union and the Junta de Castilla y León, through the Instituto para la Competitividad Empresarial de Castilla y León (ICE), with the aim of promoting knowledge transfer and cooperation between companies and research centres.

COPERNICO PROJECT

Aciturri Engineering is leading the "COPERNICO" project to be executed in 2020, 2021 and 2022. The objective of Copernicus is to obtain carbon fiber aeronautical fittings with assured process repeatability and very high cadences, which is what will be demanded in future single-aisle aircraft. In this first year we have designed and calculated fittings equivalent to the current ones to be manufactured by RTM (Resin Transfer Moulding), thus applying more modern materials, better properties and more sustainable processes. The tooling have also been manufactured by additive manufacturing, thus ensuring sustainability throughout the process. The project is funded by the “Collaboration Challenges” program of the Ministry of Science, Innovation and Universities and the State Innovation Agency.

COMMUNION

Aciturri Engineering has a contribution in the H2020 project called “COMMUNION”.

ComMUnion concept aims to be a universal solution for advance joining process for the manufacturing of hybrid 3D thermoplastic/metal composite components. Independently from the specific interest of ACIENG as end users members of the consortium, this task aims at determining the requirements of the system in order to respond to this multi-stage flexibility.

RTM Leading Edge Challenge

During the period 2016-2017, Aciturri Engineering has been leading the project “Development of leading edges in RTM”, which it is executing together with Aciturri Composites and the technology center CIDAUT, in an R&D program that forms part of the "COLLABORATION CHALLENGES" funding program. The challenge of the project is to be able to manufacture a new leading edge concept using the RTM technique and considering high production rates.

ESTENEA

Aciturri Engineering is participating as a partner in the “ESTENEA” project, “ESTUDIO DE TECNOLOGÍAS DE BAJO COSTE Y ALTAS CADENCIAS EN COMPOSITES (STUDY OF LOW-COST, HIGH-RATE TECHNOLOGIES IN COMPOSITES)”, financed by the CDTI and cofinanced by FEDER. The goal of the project, which is led by Airbus, is to search for and develop materials and processes that make it possible to undertake the manufacture of aeronautical structures at lower cost, adjusting to the increased production rate required by the market. The project began in 2014 and will continue through the end of 2017.

Aciturri, along with different technology centers such as CIDAUT, AIMEN, CTME, FIDAMC and 3T TECHNOLOGIES, is taking part in the search for materials for processes that use injected resin, and participating in the development of processes such as: additive manufacturing applied to tooling, use of lasers as an alternative to manual sanding, and optimization of simulation testing.

TARGET

TARGET aeronautical sectorial project financed by CDTI through the CENIT 2010 program and led by Airbus Operations S.L.

The project aims to research and develop new intelligent and environmentally sustainable technologies for composite structures. In this action plan, Aciturri Composites focuses its research on liquid injection processes and automation of preforming operations as an alternative to manual preforming operations or metallic solutions.

As part of this project, Aciturri is working with the CIDAUT foundation (Valladolid), a national technology center with experience in these technologies and their application in the aeronautical sector.

Additive Manufacturing, Robotics & Digital Technologies

DOMMINIO

DOMMINIO is an EU funded collaborative research project focused on the development of an innovative digital methodology to design, manufacture, maintain and pre certify multifunctional and intelligent airframe parts. The DOMMINIO project will develop an innovative methodology to ensure cost-effective, efficient, and sustainable manufacturing of high quality multifunctional and intelligent airframe parts, based on: Robotized technologies (ATL, FFF), Advanced simulation tools, On-line process & quality monitoring and SHM (Structural Health monitoring) methods enabled by real time data-driven fault detection.

For Aciturri, this project has enabled the development of important multidisciplinary tools applicable to early development stages shortening its time. Additionally initial bricks for larger scale tools for multidisciplinary optimization have been also developed.

DAAMAS

The DAAMAS (Development of wire Arc Additive Manufacturing processes for Aeronautic large Structures) Project, led by Aciturri Aeroengines, aims to develop WAAM (Wire Arc Additive Manufacturing) technology, identified as an innovative technology capable of achieving results comparable to those obtained in forging and casting processes through a more sustainable technique and with lower production costs.

This project, funded by the Institute for Business Competitiveness of Castilla y León through the MANUNET 2020 program, has as main challenges the research of a WAAM system based on MIG/MAG welding and the optimization of the manufacturing process according to aeronautical requirements.

The final objective is the development of a manufacturing device with process monitoring capabilities to ensure the traceability and quality required in our sector, in addition to achieving the full development of a selected case study.

FEÍNA PROJECT

The FEÍNA project, led by Aciturri Engineering, aims to develop additive manufacturing technology in the manufacture of titanium-based preforms to replace current forges. Additive manufacturing is a firm commitment of the Aciturri group towards more sustainable processes by optimizing the use of raw materials. Titanium is a material that combines high strength, damage tolerance and low weight properties in its alloys. This results in much lighter, more durable aeronautical parts through a much more sustainable process. During 2020 the first test detail parts have been manufactured, and it is expected to continue in 2021 and 2022 to obtain the first parts. The project is funded by the “Collaboration Challenges” program of the Ministry of Science, Innovation and Universities and the State Innovation Agency.

POLE PROJECT

The POLE Project forecast an investment of € 2 million for R&D activities within the sphere of activity of the Regional Strategy for Smart Specialisation (RIS3), is financed by the Castille and León Innovation, Finance and Business Internationalisation Agency through the European Regional Development Fund (ERDF).

With a planned duration of two years, the project is part of Aciturri’s Strategic R&D Plan for the engine segment, and involve some very demanding earning targets.

It includes technology development activities exclusively for plane engine production, primarily in two lines:

Metal products, especially advanced machining, surface technologies and automation processes.
Procurement for additive manufacturing, evaluating different technologies for each type of product.

Research on the integration of adaptive design and topological optimization with advanced manufacturing technologies for the generation of high-requirement aeronautical components - OPTIFLY3D"

The overall goal of this OPTIFLY3D project is detailed research on the integration of adaptive design and topological optimization with advanced manufacturing technologies for the generation of high-requirement aeronautical components. This aim encompasses the following specific goals:

Research, study and define families of aeronautical components that can be redesigned, optimized and manufactured using additive manufacturing technology.
Research and analyze the capabilities and viability of adaptive design and topological optimization in its application on high requirement aeronautical components.
Study and evaluate the influence of manufacturing strategies on the properties of the elements generated in additive manufacturing processes.  
Research and value the influence and possibilities of thermal and mechanical post-processes on the properties of components developed through additive manufacturing.
Study and evaluate the process times, energy consumption and materials in the integration of design processes and additive manufacturing in aeronautical elements of high requirement.
Study the costs of the complete process of adaptive design, optimization and manufacturing of aeronautical components.

RESULTS

Analysis of the elements’ physical and morphological characteristics (structure and engine) that can be optimized.
Adaptive design and topological optimization of the selected elements, maintaining their mechanical properties while reducing the amount of material used.
Definition of optimal manufacturing strategies and optimization of platforms and post-processes.
Analysis of related costs.

PROJECT SUPPORTED BY

“Optimization of the industrial process through the training of assembly personnel based on Virtual and Augmented Reality systems”

The overall goal of the project, jointly developed between PixelsHub SL and Aciturri Additive Manufacturing SLU, is the development of a virtual manual for the assembly and / or maintenance of industrial engines for internal consumption or for customers through the use of low-cost reality devices " Head Mounted Displays ".

For this purpose, the following specific technical objectives are proposed:

VIRTUAL TRAINING: Virtual Reality (HTC VIVE) to train operators in different industrial processes of Aciturri. Purpose: To develop a platform pilot for the training of assembly personnel in a virtual reality environment.
VIRTUAL ASSISTANT: Augmented Reality (HOLOLENS) to assist operators in different industrial processes of Aciturri in real time. Aim: Integrate a protocol of assembly/disassembly of the model of the different commercials into Hololens, as well as an interface that allows, at the request of the observer, to go through different parts of the protocol as it requires information in real time of the process. With this development it is intended that the operator has a manual of consultation in real time of the process in which he is immersed, thanks to the integration of the operation manual in augmented reality (Hololens).

Result:

The use of Virtual Reality has been validated for the training of the plant staff in the assembly of industrial components and the Augmented Reality as a real-time assistant for that assembly.

EWIRA

ACITURRI participates in Clean Sky 2 R+D program (within Horizon 2020 framework) leading the EWIRA Core Partner consortium; which is integrated by four members: ACITURRI Engineering and ACITURRI Assembly (Spain), CAETANO Aeronautics (Portugal) and The Manufacturing Technology Centre (UK). EWIRA activity is concentrated in introducing innovative design, manufacturing and assembly technologies in wing components of the FTB#2 flight test bed demonstrator. FTB#2 demonstrator is leaded by Airbus Defense & Space within the Regional-IADP consortium. The focus of innovation activity is in:

New assembly concepts reducing process time and costs;
Innovation in metallic machining in order to improve efficiency and reduce environmental impact;
Innovative design techniques in additive manufacturing for critical parts; and
New composite manufacturing techniques focusing on part number reduction.

SYMBIO-TIC

The European manufacturing industry is facing new challenges in terms of adaptability, flexibility and vertical integration. The SYMBIO-TIC project addresses these important issues towards a safe, dynamic, intuitive and cost effective working environment were symbiotic collaboration between human workers and robots can take place and bring significant benefits in tasks and processes that are too complex to be automated. 

In this context ACITURRI collaborates with IDEKO and PRODINTEC to shape one of the project demonstrators in which it is intended to emulate the assembly of one rib of a torsion box; in turn developing an assembly process in which the objectives and new technologies of the SYMBIO-TIC project are integrated.

SLS Aero

The general goal of the project is to undertake the necessary research for the definitive and industrial application of additive manufacturing (AM) technology in the aeronautics industry, allowing the mass production of flight parts and tooling, which is to say, to increase the TRL of metallic additive manufacturing technology in the aeronautics market.

The following specific technical objectives have been proposed to achieve this:

Determine the current capacity of AM technology using laser sintering to address the high-level requirements of the aeronautics industry.
Increase knowledge of the influence of the principal variables of the laser sintering process on the final quality of parts (structural performance, metrology, etc.).
Determine the possibility of maintaining the capacity for homogenization, repetition, and reuse of the material from AM technology, while still responding to the industry's requirements.
Determine the current capacity of AM technology using post-processing to address the high-level requirements of the aeronautics industry.
Increase knowledge of the influence of the principal variables of the post-processing processes on the final quality of parts.
Validate findings by manufacturing tests of prototypes on a laboratory scale to demonstrate the capabilities and real needs of the complete technology (laser sintering + post-processing).
Determine the most suitable process conditions that will make it possible to certify additive manufacturing processes for obtaining aeronautical components in the future.

RESULTS

Degree of homogeneity, repeatability and reuse of ALM technology materials applied to aeronautical sector requirements.

In order to study the repeatability of the process along with its quality, different experiments have been made that have allowed to analyze both mechanical properties and tolerance. Results indicate that the process is repeatable and that no significant differences are identified between the different working areas in the work platform of the SLS equipment.

Identification of the variables of operation of the laser sintering process more adequate to respond to the needs of the aeronautical sector.

We worked on the design, development and manufacture of test pieces, ad hoc parts and demonstrators. During the processes, we have evaluated the manufacturing strategies and machine parameters most appropriate to get the best results both from the dimensional and physical-mechanical point of view of each element. This experience has served to establish the most appropriate manufacturing methodologies to build right parts, guarantee repeatability of the process and its homogeneity.

Finishes and dimensional tolerance.

High requirements required in finishing and dimensional tolerance are characteristic of the manufacturing processes of the aeronautical sector. Inside this framework, analyzes, experiments and studies related to different technologies have been made, complementing the SLS, allowing to improve surface finish and achieve the required dimensional tolerance.

Identification of suitable materials for the aeronautical sector within the families of metal alloys previously identified as more appropriate.

Inside of aeronautics requirements, the metallic materials used are characterized by providing adequate mechanical properties with the smallest weight as possible. In this case, one of the materials most used is a titanium alloy (Ti6Al4V), which brings lightness at the same time as resistance. The studies made in the SLSAero project have focused on the analysis of this material and the results have been positive. Titanium alloys processed by SLS have high capacities for the aeronautical sector.

COROMA

To progress in the scientific and technological development of robotics is one of the pillars of Industry 4.0 and constitutes one of the priority action axes marked by the European Commission to boost the competitiveness of the industrial sector in Europe.

The European project COROMA (Cognitively Enhaced Robot For Flexible Manufacturing of Metal and Composite Parts), an initiative coordinated by the technology centre IK4-IDEKO and in which Aciturri participates as final user of the advancements, is developed in this context. It seeks to develop a new concept of intelligent, modular and flexible industrial robots, with the capacity to execute multiple processes and to manufacture metallic and composites detail parts for sectors as demanding as aeronautics.

The robotic system will be able to perform drilling, trimming, deburring, polishing, sanding, non-destructive inspection and adaptive fixation. Using a simple interface, it will receive basic commands that will require minimal programming effort from the operator. In addition, it will move autonomously in the production plant, perceiving the manufacturing environment and locating the elements to be manipulated, even using the required tools for the processing of the pieces.

IMPACT - lighter protection systems for Defense through 3D printing

The IMPACT project is aimed at the "3D printing of new auxetic materials and structures for the improvement of passive protection systems for combatants" and is part of the R&D projects of interest for Defense included in the scope of the Program for Cooperation in Scientific Research and Development in Strategic Technologies (Coincident Program).

The fundamental concept of IMPACT is the design, development, fabrication and validation of reticular structures with auxetic properties. Auxetic structures and materials are those that have a negative Poisson's coefficient, which means that their behavior is the opposite of that usually expected when subjected to tensile/compression processes: when subjected

to traction [compression] in the axial direction, an expansion [compression] is produced in the transverse direction. This characteristic makes the combination of these materials and structures ideal for protection systems and, as on other occasions, opens up a wide range of opportunities for their application in other sectors by combining lightness and strength in structures that until now had to be solid.

The scope of the project includes the validation of test specimens in different commercial materials, and also includes the specific development of a steel with ballistic quality, atomizable and processable through 3D printing technologies.

The project, sponsored and supervised by the General Directorate of Armament and Material of the Ministry of Defense of the Spanish Government, is led by Fundación Idonial and, together with Aciturri Additive Manufacturing SLU, ArcelorMittal Innovación Investigación e Inversión, SL and Fundación CIDETEC are participating in its development.

Space & Diversification

StarFab

As part of the European Horizon Europe research program, Sonaca has joined the consortium led by Space Applications Services to design the first prototype of an automated warehouse in zero gravity.

Launched in 2024, the StarFab project explores the future of a space‑based logistics economy and aims to contribute to a more sustainable space infrastructure.

SHERPA

Aciturri Engineering has received a grant for the execution of the Research and Development project entitled SHERPA ("SUSTAINABLE AND COMPETITIVE SOLUTIONS FOR SMALL SPACE LAUNCHER HULLS") through the Center for Technological Development and Innovation (CDTI), a grant co-financed with FEDER funds, with project number IDI-20221104.

The SHERPA project was born with the general objective of developing the necessary technology to respond in the short term to the need for low weight, low cost and short development time solutions to the payload hulls of small launchers while respecting the requirements of minimum environmental impact. It is a response to the Aciturri Group's diversification strategy towards the space sector.

Place of execution: Madrid

Execution period: 06/01/2022 to 03/31/2024

Grant received from CDTI: 1,129,141.70 €.

MADTIGER

Sonaca and EHP develop disruptive satellite panels with integrated thermal management systems in this ESA project.

SPACESHIP

Sonaca and partners develop smart cryogenic tanks with SHM solutions in this ESA project

ASTRALIS

Sonaca and partners develop a space service station for satellites ; Sonaca will be in charge of the structure of the satapps logistic module

Sustainable Materials & Bio Composites

FASTER H2

The objective of the FASTER H2 project is to develop a highly integrated aircraft fuselage demonstrator based on the use of thermoplastic materials, which are recognized as sustainable materials due to their reusability and the manufacturing technologies used to process them, including one of the most advanced methods, in situ consolidation manufacturing. Additionally, infusion processes will be developed and validated, focusing on ensuring the robustness of the industrial process that allows its application at high production rates, based on bio-based resins, focusing on sandwich panel configurations and integrated double-curved skins using LRI technology, and fittings using RTM technology.

Until now Aciturri has worked on this project designing the tooling necessary for the manufacture of the stiffeners that will be integrated into the final demonstrator through the in situ consolidation (IsC) process, analyzing manufacturing capabilities, reviewing the stamping process, and the general process parameters.

Additionally, in line with improving the sustainability of our components, the first manufacturing tests have also been carried out with a newly developed "Bio" resin for the LRI and RTM infusion processes.

With Aciturri's participation in this project, progress will be made in the development of thermoplastic materials, as a greener technology due to their recyclability, applicable to aerostructures, and a deeper understanding of the infusion processes (LRI & RTM) will be achieved, especially using bio-resins compared to other commercial resins, thus promoting the use of eco-friendly materials in our products.

Rlightbiocom

Aciturri participates in the r-LightBioCom project - New bio based and sustainable Raw Materials enabling Circular Value Chains of High Performance Lightweight BioComposites - which aims to reduce the environmental impact of new lightweight high performance composite materials. Not only during their production, but also during their operational life and after reaching their final service life, due to their inherent recyclability properties. While providing improved mechanical properties, weight reduction and new functionalities.

The r-LightBioCom consortium, led by Aitex, is made up of the industrial companies Aciturri, Acciona Construcción and the Centro Ricercje FIAT; together with the universities and research centers Universitat Politècnica de Catalunya, Hochschule Kaiserslautern, Coventry University, Leibniz-Institut für Verbundwerkstoffe GmbH, DLR and CIDAUT; as well as the companies AEP Polymers, Feyecon and FECSA.

Aciturri's role in this project is to contribute with its experience in the use of composite materials for the manufacture of aerospace elements for the characterization of the new materials developed. Finally, a test case will be carried out to verify the validity of the new components and the fulfillment of the performance required for their implementation in the aviation sector.

Future Air Mobility

Wisk

Sonaca contributes to shaping the future of aviation. Wisk is one of the flagship projects supporting this vision. As a major supplier, Sonaca helps develop and operate the first certified, fully autonomous, electric vertical take‑off and landing (eVTOL) air taxis, aiming to provide safe, sustainable and accessible air mobility for everyday use.

FRUAM

The R&D Strategic Plan FRUAM (Future Urban and Regional Air Mobility) presented by Aciturri Aerostructures SLU aims to develop new technologies and processes that allow the industrialization associated with the manufacture of aircraft that will meet the needs arising from the new types of mobility for urban and regional areas.

Additionally, among other benefits, FRUAM will allow Aciturri Aerostructures to undertake the paradigm shift that the aeronautical industry will demand from the high cadences that are expected to supply a new type of aircraft, propelled by electric engines, with vertical take-off and landing (eVTOL - Electric Vertical Take Off and Landing).

The Strategic Plan is included within the thematic priorities and areas of action identified in the "Regional Strategy for Research and Innovation for a Smart Specialization RIS3 of Castilla y León", specifically in Priority 2 "Productive efficiency in transport sectors such as automotive and aeronautics, making materials and components the keys to leadership and sustainability", Area 2.4 "R&D&I in Design and Manufacturing".

FRUAM has been co-financed by FEDER, Thematic Objective 1, which seeks to promote technological development, innovation and quality research and is framed within Investment Priority 1. Encouragement and promotion of R&I activities led by companies and support for the creation and consolidation of innovative companies of the Thematic Objective OT1 "Promoting research, technological development and innovation" corresponding to FEDER OP for Castilla y León 2014-2020.

Defense

NGCAT

In the ROCALIF project, Sonaca with its partners develop technologies centered on remote carriers (RC - mid sized drones which will be surrounding the Next Generation Fighter in the future). The major aim is to enable high rate composite production, but also reduce the RC observability.

In the AMOSKA project, Sonaca and partners develop a morphing flaperon, which will reduce the observability of the future fighters.

In the EATMI project, the European consortium develops technologies for the hypersonic interceptors, for which Sonaca is in charge of the major part of the airframe, and the interstage separation devices.

*Before joining Sonaca Group, Aciturri was a leading Tier‑1 aerospace supplier. The solutions developed during that period remain an essential part of Sonaca’s technological heritage and innovation journey today.