Development of a Design for Manufacturing and Assembly (DFM/A) methodology concerning products and components made in composites of Carbon Fiber Reinforced Plastics (CFRP) used in the Aerospace Industry

Composites of carbon fiber reinforced plastics (CFRP) are being used to a greater extent in the aerospace industry due to their desired material properties. CFRP are attractive to use since they are light, strong and make it possible to integrate parts in in ways not possible in other materials. However, using CFRP is challenging since they may lead to more problems in final assembly. The aim of this paper is to describe the development of a Design for Manufacturing and Assembly (DFM/A) methodology for manufacturing aircraft structures in CFRP. The research methodology consisted of interviews, observations, workshops and tests at SAAB Aerostructures, but also interviews with other companies regarding their design for manufacturing methods. The result is a methodology that includes an approach that describes when and how the DFM/A work should be conducted and organized, and how it is linked and integrated into the company’s product development process. The DFM/A methodology developed makes it possible to include manufacturing aspects into the existing product development process to ensure that manufacturing is considered in the design phase, with special focus on CFRP.