CA3ViAR · Project

Validated Test Data for Safer, Quieter Next-Generation Aircraft Engine Fan Blades

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Imagine the big spinning fan you see at the front of a jet engine — future engines need those fans to be much larger and made of lightweight composites to burn less fuel. But bigger, lighter blades can vibrate dangerously or make too much noise, and engineers don't have enough real test data to predict when that happens. This project built a purpose-designed fan, put it in a wind tunnel in Germany, and measured exactly how and when these blades start to flutter, stall, or get too loud. The result is an open dataset that any engine designer can use to validate their computer models before committing to expensive prototypes.

By the numbers

EUR 2,296,875

EU research investment in fan validation technology

consortium partners across 3 countries

technical deliverables produced

60%

industry partner ratio in the consortium

SMEs involved in the project

The business problem

What needed solving

Aircraft engine manufacturers are racing to build ultra-high bypass ratio (UHBR) turbofans with larger, lighter composite fan blades that reduce fuel consumption and noise. But these bigger composite blades are prone to dangerous vibration modes like flutter and stall, and engineers lack sufficient validated test data to trust their computer simulations. Getting it wrong means costly redesigns or — worse — in-service failures that ground fleets.

The solution

What was built

The team designed and manufactured a Low-Transonic Fan (LTF) test article using composite materials, ran it through acceptance tests, and performed comprehensive wind tunnel experiments at TU Braunschweig's propulsion test facility. They delivered validated aerodynamic, aeroelastic, and aeroacoustic models calibrated against real experimental data, packaged across 12 deliverables.

Audience

Who needs this

Aircraft engine OEMs developing next-generation UHBR turbofans (Rolls-Royce, Safran, GE Aviation, MTU)Tier-1 suppliers manufacturing composite fan blades and engine componentsAerospace CFD/FEA simulation software companies needing validation benchmarksAerospace testing and certification service providersUniversity and research institute labs building turbomachinery test capabilities

Business applications

Who can put this to work

Aerospace Engine Manufacturing

enterprise

Target: Aircraft engine OEMs and tier-1 suppliers developing UHBR turbofan engines

If you are an engine manufacturer designing the next generation of ultra-high bypass ratio turbofans — this project produced an open-test-case fan geometry with validated aerodynamic, aeroelastic, and aeroacoustic wind tunnel data. Instead of running your own multi-million-euro test campaigns from scratch, you can calibrate your simulation tools against this dataset and catch flutter or stall problems earlier in the design cycle.

Composite Aerospace Components

mid-size

Target: Manufacturers of composite fan blades and aerospace structural parts

If you are a composite parts manufacturer expanding into engine fan blades — this project tested a composite Low-Transonic Fan article through acceptance tests and full wind tunnel validation across a wide range of operating conditions. The manufacturing lessons and instability data from this 5-partner, 3-country consortium can help you understand failure modes specific to composite fan geometries before you invest in your own production tooling.

Aerospace Simulation Software

any

Target: Companies developing CFD, FEA, or aeroelastic simulation tools for turbomachinery

If you are a simulation software vendor and your customers keep asking whether your flutter and stall predictions match reality — this project generated a comprehensive open benchmark dataset covering aerodynamics, aeroelasticity, and aeroacoustics from controlled wind tunnel tests. You can use this data to validate and market your solvers against a publicly available, industry-relevant test case with 12 documented deliverables.

Frequently asked

Quick answers

How much did this research cost and what would access to the results cost us?

The EU invested EUR 2,296,875 in this project under Clean Sky 2. The project aimed to produce an open-test-case fan geometry, meaning the test data is intended for broader use. Specific licensing or access costs would need to be discussed with the coordinator IBK-Innovation GmbH.

Can these results be applied at industrial scale for real engine development?

The fan was tested in an established propulsion test facility (PTF) at TU Braunschweig, which is a recognized aerospace wind tunnel. The test conditions were designed to be representative of real UHBR engine fan behavior including stall and flutter. However, moving from wind tunnel validation to a full-scale engine certification program requires additional development steps.

What is the IP situation — can we use these designs and data?

The project was explicitly designed around an open-test-case fan geometry, which suggests the intent was to create a shared benchmark. However, specific IP ownership across the 5-partner consortium and any restrictions on commercial use should be clarified directly with the coordinator. Clean Sky 2 projects typically have defined IP frameworks.

Does this meet aviation regulatory requirements?

The project focused on generating validated experimental data and calibrating simulation models, not on certifying a specific engine component. The data would support future certification efforts by providing validated aeroelastic and aeroacoustic models, but certification of any production fan blade would require separate regulatory processes.

How long did the project run and what was delivered?

The project ran from September 2019 to December 2023 and produced 12 deliverables. Key outputs include the designed Low-Transonic Fan (LTF) test article, acceptance test results verifying its functionality, and validated aerodynamic, aeroelastic, and aeroacoustic models calibrated against wind tunnel data.

Can these tools integrate with our existing simulation workflow?

The project's final phase focused on calibrating and validating aerodynamic, aeroelastic, and aeroacoustic models against the wind tunnel test data. This means the outputs are designed to serve as validation benchmarks for existing commercial and in-house simulation codes rather than as standalone software tools.

Who built this and can they support further development?

The consortium was led by IBK-Innovation GmbH (Germany, SME) and includes 5 partners across Germany, Greece, and Italy — with 3 industrial partners including composite manufacturer ADC. The mix of university aerodynamics expertise and industry manufacturing capability means the team could potentially support follow-on testing or consultancy work.

Consortium

Who built it

This is a compact, industry-heavy consortium with 5 partners across Germany, Greece, and Italy — 60% from industry and 3 out of 5 being SMEs. The coordinator IBK-Innovation GmbH is a German SME specializing in innovation engineering, supported by Italian composite manufacturer ADC for the actual blade fabrication. The academic side is strong: TU Braunschweig provided the wind tunnel facility and led aerodynamic design, while Leibniz Universität Hannover led model validation. This setup — SME coordination, specialized manufacturing, and top-tier university testing facilities — is typical of Clean Sky 2 projects where the goal is to de-risk specific engine technologies for eventual use by the large OEMs like Rolls-Royce, Safran, or MTU.

IBK-INNOVATION GMBH & CO. KGCoordinator · DE
DREAM INNOVATION SRLparticipant · IT
ADAMANT AERODIASTIMIKES EFARMOGES ETAIREIA PERIORISMENIS EFTHYNISparticipant · EL
TECHNISCHE UNIVERSITAET BRAUNSCHWEIGparticipant · DE
GOTTFRIED WILHELM LEIBNIZ UNIVERSITAET HANNOVERparticipant · DE

How to reach the team

IBK-Innovation GmbH & Co. KG (Germany) — contact via project website or SciTransfer introduction

Order a report on this consortium See IBK-INNOVATION GMBH & CO. KG profile →

Next steps

Talk to the team behind this work.

Want access to this validated fan testing data or an introduction to the consortium? SciTransfer can arrange a direct conversation with the right technical lead.

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