DOVER · Project

Software Tool That Designs Lighter, Stronger Composite Aircraft Wings Faster

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Imagine you're building a wing out of carbon fiber panels, and each panel has stiffening ribs glued onto it — like the ribs of an umbrella. Where those ribs end is a weak spot that can crack under stress. Right now, figuring out the best shape and layout for those rib endings requires expensive computer simulations and physical crash tests. DOVER built a design tool that predicts where and how cracks will start, so engineers can optimize the wing structure on screen — without needing to build and break dozens of expensive test pieces first.

By the numbers

EUR 742,430

EU contribution under Clean Sky 2

41 months

Project duration

3 partners

Consortium size, all based in Spain

67%

Industry partner ratio in consortium

Total project deliverables

The business problem

What needed solving

Designing composite aircraft wings involves stiffener run-outs — the points where structural ribs taper off — which are critical failure zones. Today, engineers rely on expensive finite element simulations and physical test campaigns to validate each configuration, burning months of development time and significant budget on destructive testing.

The solution

What was built

A design optimization tool and validated methodology for composite wing panel stiffener run-outs. The project delivered 8 deliverables including manufactured test specimens (mono and multi-stiffened panels by SOFITEC) and experimental validation covering stress, strain, damage tolerance, and fatigue life.

Audience

Who needs this

Tier 1 aerostructure suppliers manufacturing composite wing panels for Airbus or BoeingComposite design consultancies running structural optimization for aerospace clientseVTOL and urban air mobility startups designing lightweight composite airframesAircraft MRO companies evaluating composite structural repairsDefense aerospace contractors designing next-generation composite wing structures

Business applications

Who can put this to work

Aerospace structures manufacturing

enterprise

Target: Tier 1 or Tier 2 aerostructure suppliers producing composite wing panels

If you are a composite wing panel manufacturer spending months on testing stiffener run-out configurations — this project developed a validated design optimization tool that predicts failure without complex numerical models. It covers geometry, stacking sequences, and anti-peeling fastener layouts, cutting the need for expensive physical test campaigns. The tool was validated over a 41-month programme with 3 partners and 8 deliverables.

Composite materials engineering

mid-size

Target: Engineering consultancies specializing in lightweight composite design for transport

If you are a composites engineering firm that runs FEA simulations for clients in aerospace — this project created a methodology that replaces complex numerical models with faster failure-prediction criteria for stiffener run-outs. Test specimens including multi-stiffened panels were manufactured by SOFITEC and validated experimentally, covering stress, damage tolerance, and fatigue life.

Urban air mobility and drone manufacturing

any

Target: eVTOL or large drone manufacturers designing composite airframes

If you are building next-generation air vehicles with composite wings and need to minimize weight while meeting certification loads — this project delivered an optimization environment for stiffener geometry, thicknesses, lay-ups, and tapering shapes. The methodology was validated through experimental testing on mono and multi-stiffener panels, giving confidence in results without full-scale physical tests.

Frequently asked

Quick answers

What would it cost to license or adopt this design tool?

The project was funded with EUR 742,430 in EU contribution under Clean Sky 2. Licensing terms would need to be negotiated directly with Universidad de Sevilla and the industrial partners. Based on available project data, no commercial pricing has been published.

Can this tool work at industrial scale for full wing design?

The tool was validated on mono and multi-stiffener panels, including specimens manufactured by SOFITEC. It is designed to optimize full wing structural composite panels, but scaling to complete wing sections would likely require further integration with existing design workflows.

Who owns the intellectual property?

The project ran under Clean Sky 2 (CS2-RIA), which typically means IP is shared between the consortium and the Clean Sky 2 Joint Undertaking. The 3-partner consortium — 2 industrial, 1 university — all based in Spain, would hold specific rights. Exact licensing arrangements should be discussed with the coordinator.

How much time does this tool actually save compared to traditional testing?

The objective states considerable time savings because the tool does not require complex numerical models to predict behaviour and eliminates the need for expensive testing campaigns. Based on available project data, specific time reduction percentages were not published in the accessible deliverables.

What types of composite configurations does it cover?

The tool handles stiffener geometry, thicknesses, lay-ups of different components, shape of the tapering, and anti-peeling fastener configurations. It was experimentally validated for stress, strain, damage tolerance, and fatigue life on optimized stiffener run-out configurations.

Does this meet aerospace certification requirements?

The methodology was validated through experimental testing including damage tolerance and fatigue life — both critical for certification. However, based on available project data, formal certification by EASA or other authorities was not part of the project scope. Results feed into Clean Sky 2's broader certification pathway.

Consortium

Who built it

This is a tightly focused, all-Spanish consortium of 3 partners with a strong industrial lean — 2 out of 3 partners are from industry (67%), with Universidad de Sevilla providing the academic backbone. SOFITEC, named in the deliverables as the manufacturer of test specimens, is a well-known Spanish aerostructures company supplying Airbus. The absence of SMEs and the Clean Sky 2 funding scheme signal this is aimed squarely at large-scale aerospace OEM supply chains. The single-country setup means efficient collaboration but limited pan-European market reach without additional partnerships.

UNIVERSIDAD DE SEVILLACoordinator · ES
SOFITEC AERO SLparticipant · ES

How to reach the team

Universidad de Sevilla, aerospace engineering department — reachable through the university's research office or the project website

Order a report on this consortium See UNIVERSIDAD DE SEVILLA profile →

Next steps

Talk to the team behind this work.

Want to explore how this composite wing optimization tool could reduce your design cycle costs? SciTransfer can connect you with the DOVER team.

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