ANTIFOD · Project

Aircraft Engine Inlet Protection Device That Stops Foreign Object Damage Before It Happens

transportTestedTRL 5

Imagine your car engine had an open air intake driving down a gravel road — rocks, dust, and debris would wreck it fast. Aircraft engines face the same problem: birds, ice, stones, and runway debris get sucked into air inlets and cause expensive damage or dangerous failures. ANTIFOD built a physical protection device — like a smart filter — that sits at the fresh air inlet of an aircraft's electrical environmental control system, separating out dangerous debris before it reaches the turbocompressor. They designed it using computer simulations and 3D printing, then built a full-scale working prototype and tested it in real conditions.

By the numbers

TRL5

Technology readiness level achieved — validated in relevant environment

Consortium partners across 2 countries

60%

Industry participation ratio in consortium

Countries involved (Spain, UK)

Industry partners in the consortium

The business problem

What needed solving

Foreign Object Debris (FOD) — birds, ice, stones, and runway debris — gets sucked into aircraft air inlets and damages expensive turbocompressor components in environmental control systems. This leads to costly unplanned maintenance, flight delays, and safety risks. The aviation industry needs reliable protection devices that block debris without restricting airflow or adding excessive weight.

The solution

What was built

A full-scale FOD protection and separation device for aircraft electrical ECS fresh air inlets, validated to TRL5. The consortium delivered a working prototype to the Clean Sky 2 Topic Leader along with a communication, dissemination and exploitation plan covering IPR management.

Audience

Who needs this

Aerospace OEMs building next-generation electrical environmental control systemsAircraft MRO companies dealing with FOD-related turbocompressor repairsAirport operators investing in FOD prevention programsIndustrial turbocompressor manufacturers facing debris ingestion in harsh environmentsDefense aviation contractors requiring ruggedized air intake protection

Business applications

Who can put this to work

Aerospace MRO & Component Manufacturing

enterprise

Target: Aircraft component manufacturers and MRO providers

If you are an aerospace component manufacturer or MRO provider dealing with costly foreign object damage repairs on environmental control systems — this project developed a full-scale FOD protection device validated to TRL5 that separates debris before it reaches turbocompressors. The design was verified using both CFD simulation and additive manufacturing prototypes across a 5-partner consortium with 60% industry participation.

Aviation Ground Operations

enterprise

Target: Airport operators and ground handling companies

If you are an airport operator struggling with FOD incidents on runways that damage aircraft systems and cause flight delays — this project developed an inlet protection device that captures foreign objects before they enter aircraft air systems. The technology was tested at full scale and delivered as a working prototype, addressing a problem that costs the aviation industry significantly in unplanned maintenance.

Industrial Turbocompressor Systems

mid-size

Target: Turbocompressor and HVAC system manufacturers

If you are a turbocompressor manufacturer dealing with debris ingestion damaging your equipment in harsh environments — this project developed a separation device originally designed for aircraft ECS turbocompressors that could be adapted for industrial air intake protection. The two-stage design process included aerodynamic geometry optimization and Wall-Modelled LES simulations to minimize pressure loss while maximizing debris separation.

Frequently asked

Quick answers

What would this cost to license or integrate into our systems?

The project does not publish pricing or licensing terms. The technology was developed under the Clean Sky 2 program (JTI-CS2) with specific IP arrangements. Contact the coordinator at Universitat Politecnica de Catalunya or the industrial partners to discuss licensing terms.

Can this scale to full production for commercial aircraft fleets?

The device was validated to TRL5, meaning it was tested in a relevant environment at full scale. Moving to production (TRL7-9) would require additional certification testing and manufacturing scale-up. The consortium included 3 industry partners, which suggests manufacturing know-how is already involved.

Who owns the intellectual property?

IP was developed under Clean Sky 2 Joint Undertaking rules. The consortium of 5 partners across Spain and the UK shares rights according to their grant agreement. The communication and exploitation plan deliverable covers IPR management — contact the coordinator for specifics.

Does this meet aviation safety regulations?

The device was designed to meet user requirements defined by the Clean Sky 2 Topic Leader and validated through a preliminary design review (PDR) demonstrating compliance. Full aviation certification (e.g., EASA) would be a next step beyond the TRL5 validation achieved in this project.

How long did development take and what is the current status?

The project ran from November 2018 to January 2022, roughly 3 years. It is now closed. The final deliverable was a full-scale working prototype delivered to the Topic Leader.

How does this integrate with existing aircraft systems?

The device was specifically designed to integrate with the mechanical interfaces of the existing intake scoop inlet, scoop ducting, and eECS inlets. The aerodynamic geometry was optimized to minimize pressure loss while maximizing FOD separation efficiency.

Consortium

Who built it

The ANTIFOD consortium is compact but industry-heavy: 5 partners from Spain and the UK, with 3 industry players and 2 universities, giving a 60% industry ratio. This is a strong signal for business relevance — the technology was not built in an academic vacuum. Two of the partners are SMEs, meaning smaller specialized companies contributed manufacturing or engineering expertise. The coordinator is Universitat Politecnica de Catalunya, a well-known Spanish technical university. The Clean Sky 2 program context means this was developed with direct input from a major aerospace OEM acting as Topic Leader, who received the final prototype.

UNIVERSITAT POLITECNICA DE CATALUNYACoordinator · ES
THE UNIVERSITY OF MANCHESTERparticipant · UK
AIRCRAFT RESEARCH ASSOCIATION LIMITEDparticipant · UK

How to reach the team

Universitat Politecnica de Catalunya (Barcelona, Spain) — look for the aerospace or fluid mechanics engineering department leads involved in Clean Sky 2 projects

Order a report on this consortium See UNIVERSITAT POLITECNICA DE CATALUNYA profile →

Next steps

Talk to the team behind this work.

Want an introduction to the ANTIFOD team to discuss licensing this FOD protection technology? SciTransfer can arrange a direct meeting with the right people.

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