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Innovation in Aerospace: Advanced composites and additive manufacturing process presented by Dr. Tamas Havar, Sr. Manager for Additive Manufacturing, Blue Origin LLC

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About the event


Current aircraft and spacecraft are using more and more advanced composites and additive manufactured part in order to decrease carbon footprint by reducing weight and increased integration of parts. With increased global competition within the aerospace market a high focus is also reducing costs of newly developed parts and to simplify the integration and certification. Two examples are presented on how to best integrate new innovation within the aerospace business. The first example shows a step by step approach to develop a flap composite load introduction rib with advanced manufacturing and analysis methods. The new design of the flap load introduction rib and drive rib further integrates lugs for the attachment of the flap support structure and flap drives. The aim of the new design was to decrease manufacturing costs as well as minimizing the manufacturing costs by an automatable preform lay-up and industrial concept. This is further enhanced by the application of a vacuum infusion process (VAP), outside the autoclave saving additional manufacturing costs. The influence of pre-form 3D stitching, assembly and structural stitching, on the mechanical properties of the material is investigated in detail as well. The second example present an end to end additive manufacturing process and the current challenges regarding stable and repeatable manufacturing, which are requirements for aerospace certification of new metal parts.


Dr. Havar has been leading engineering, production, operations and R&D at Airbus, Boeing, Blue Origin and Tier1’s for over 20 years. He has lead global teams and international departments in the field of disruptive innovations, additive manufacturing (3D printing), innovative composites, new electrical components, integration and assembly as well as airworthiness certification. He obtained a PhD from the University of Stuttgart, Germany in 2007, a master’s degree also from University of Stuttgart in 2001. He served on the board for handbook for aircraft structures used for aircraft certification and received an award at the European Conference for Composite Materials in 2014. He holds more than 10 patents in the field of aerospace and has several publications.

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