NSLGP · Project

Lighter, Cheaper Composite Landing Gear Parts for Helicopters and Aircraft

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Imagine the heavy metal parts on an airplane's landing gear — the covers, fairings, and brackets that don't carry the main structural load but still add a lot of weight. This project figured out how to make those parts from advanced carbon fiber composites instead of metal, making them significantly lighter while still surviving the brutal conditions of takeoff and landing. The team also developed automated manufacturing methods to keep costs down and simplify how the parts are assembled. Think of it like replacing the heavy steel panels on a car with tough, lightweight carbon fiber — same protection, far less weight.

By the numbers

consortium partners (all industry)

countries involved (Germany, Israel)

100%

industry participation ratio

total project deliverables

SME partner in consortium

The business problem

What needed solving

Aircraft and helicopter operators lose fuel efficiency and payload capacity because many landing gear components are still made from heavy metals, even when those parts serve no structural load-bearing function. Replacing them with lighter materials has been held back by the cost of composite manufacturing and the complexity of aerospace certification. Manufacturers need proven, cost-effective composite parts that can survive the extreme conditions of landing gear operation — vibration, impact, temperature swings, and moisture.

The solution

What was built

The team manufactured carbon fiber composite demonstrator parts and coupon test elements for non-structural landing gear applications. They developed automated manufacturing processes, optimized part designs for weight reduction, simplified assembly methods, and defined a certification pathway — delivering 4 project deliverables in total.

Audience

Who needs this

Aircraft OEMs looking to reduce airframe weight on next-generation platformsHelicopter manufacturers seeking fuel efficiency gains through lighter landing gearTier-1 landing gear system suppliers wanting composite alternatives to metal partsComposite manufacturers seeking validated aerospace production processesMRO providers interested in lighter replacement parts for fleet upgrades

Business applications

Who can put this to work

Aerospace Manufacturing

enterprise

Target: Aircraft and helicopter OEMs or Tier-1 landing gear suppliers

If you are an aerospace manufacturer dealing with weight penalties on landing gear assemblies — this project developed carbon fiber composite replacements for non-structural landing gear parts that deliver weight reduction while sustaining harsh environmental conditions. The automated manufacturing process was designed for low-cost production, which could reduce your per-part cost compared to traditional metal machining. Demonstrator parts were manufactured and tested by a 2-partner, 100% industry consortium.

Rotorcraft & Helicopter Services

enterprise

Target: Helicopter manufacturers and MRO providers

If you are a helicopter manufacturer or maintenance provider struggling with heavy landing gear components that drive up fuel costs — this project produced composite non-structural landing gear parts specifically designed for rotorcraft applications. The parts were validated to withstand harsh environmental conditions. With assembly simplification built into the design, your maintenance turnaround times could also improve.

Advanced Composites Manufacturing

SME

Target: Carbon fiber part manufacturers seeking aerospace contracts

If you are a composites manufacturer looking to enter or expand in the aerospace landing gear supply chain — this project developed and validated automated manufacturing processes for carbon fiber non-structural parts. The work included design optimization for weight reduction and a defined certification pathway. CirComp, the SME partner, demonstrated these capabilities alongside Israel Aerospace Industries across 4 deliverables.

Frequently asked

Quick answers

What would it cost to adopt these composite landing gear parts?

The project does not disclose specific part costs or pricing. However, the objective explicitly targets low-cost production through automated manufacturing and assembly simplification. For pricing on specific part geometries, direct engagement with the consortium partners would be needed.

Can this be produced at industrial scale?

The project improved automated manufacturing processes specifically for scalability. Demonstrator parts and coupon elements were manufactured by both IAI and CirComp. The 100% industry consortium — with no universities involved — signals a production-oriented focus rather than pure research.

What is the IP and licensing situation?

This was a Clean Sky 2 Innovation Action (CS2-IA), which typically means IP stays with the consortium partners. Israel Aerospace Industries and CirComp would be the primary IP holders. Licensing terms would need to be negotiated directly with them.

Has this been certified for use on actual aircraft?

The project described a certification process as part of its scope. Based on available project data, demonstrator parts were manufactured and tested, but full airworthiness certification details are not documented in the public data. The certification pathway was defined but completion would need to be confirmed with the coordinator.

How much weight can actually be saved?

The objective states weight reduction as a primary goal through design optimization and material substitution from metal to carbon fiber composites. Specific weight savings percentages are not published in the available project data. Typical metal-to-composite substitutions in aerospace yield 20-40% weight savings, but this would need to be verified with IAI directly.

What specific parts were developed?

The project focused on non-structural landing gear parts for both helicopters and fixed-wing aircraft. Deliverables include coupon elements and demonstrators manufactured by both IAI and CirComp. These are the covers, fairings, brackets, and similar components that are not load-bearing structural members.

Consortium

Who built it

This is a lean, fully industrial consortium with just 2 partners across Germany and Israel — no universities or research institutes. Israel Aerospace Industries (IAI) is a major defense and aerospace OEM, while the German partner CirComp is an SME specializing in composite manufacturing. The 100% industry ratio and zero academic involvement is unusual and signals that this project was firmly focused on production-ready technology rather than exploratory research. For a business buyer, this means the technology was developed by companies that actually build and sell aerospace parts, not by a lab that would need years to commercialize. The international pairing of a large OEM with a specialized SME manufacturer also suggests the supply chain integration has already been considered.

ISRAEL AEROSPACE INDUSTRIES LTD.Coordinator · IL

How to reach the team

Israel Aerospace Industries LTD (IAI), Israel — contact through SciTransfer for a warm introduction to the project team

Order a report on this consortium See ISRAEL AEROSPACE INDUSTRIES LTD. profile →

Next steps

Talk to the team behind this work.

Want to explore composite landing gear parts for your fleet or supply chain? SciTransfer can connect you directly with the IAI team and provide a tailored technology brief. Get in touch.

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