NIAR develops novel overmolded thermoplastic production process for EVTOL applications

The National Institute for Aviation Research (NIAR) at Wichita State University has engineered an advanced thermoplastic rib structure, showcasing the potential of fully automated hybrid thermoforming and injection overmolding.

The program, led NIAR’s Advanced Technologies Lab for Aerospace Systems (ATLAS) cuts production time from 100 hours to two minutes, marking a major breakthrough in aerospace manufacturing efficiency. By integrating two key polymer processing techniques, the process enables the production of high-performance, lightweight components with greater design flexibility and cost efficiency.

The development was part of the Air Force Research Laboratory’s Manufacturing for Affordable Sustainable Composites program and was made possible through collaboration with industry leaders, including Joby Aviation, Toyota, KraussMaffei, Victrex, and Prospect.

“This was a particularly challenging component, traditionally machined from a metal billet—a processphoto of the overmolding aircraft part that removes over 80 percent of the material and takes more than 100 hours to complete,” said Dr. Waruna Seneviratne, director of NIAR ATLAS. “In contrast, the thermoplastic part was formed from a flat thermoplastic organosheet in under two minutes. The expertise of each partner was instrumental in achieving this success.”

Last year, NIAR researchers collaborated with KraussMaffei to develop a thermoplastic overmolded window cover for passenger-to-cargo conversions that can be produced in just 90 seconds. The resulting component was 20–30 percent lighter and cost half as much as its metal counterpart.

“These advancements underscore the potential of automotive-matured overmolding technology for high-rate production of both primary and secondary aircraft structures,” said Seneviratne.

Eugen Schubert, an application engineer at KraussMaffei, emphasized the value of NIAR’s ATLAS facility in fostering innovation.

“It provides a collaborative environment where equipment manufacturers, material suppliers, and tool designers can partner with aircraft manufacturers to de-risk the introduction of new materials and processes in demanding aerospace applications,” he said.

The project has also expanded its collaboration to include Fill Engineering, aiming to develop a fully integrated manufacturing cell for rib structure production. This advanced system will incorporate material preparation, tape-laying, ultrasonic tack welding, consolidation, organosheet trimming, and overmolding. The production cell is scheduled for commissioning at NIAR in the fall of 2025.

In addition, researchers have broadened their study to include thermal, physical, and mechanical testing to validate process repeatability and ensure part quality. These efforts will provide crucial certification guidance for overmolded aircraft structures.

“NIAR’s work aligns with the aerospace industry’s ongoing shift toward sustainable, high-performance materials and advanced manufacturing techniques that improve efficiency while reducing costs,” said Seneviratne. “As high-rate production methods continue to gain traction, innovations like these could play a pivotal role in the future of aerospace manufacturing.”