I. Core Breakthroughs

Breakthrough 1 : Innovative attempt AFP+PBF One-step titanium part RTM Co-molding OGV Complete engineered process

Tradition OGV Using all‑metal integral forging or post‑riveting titanium joints to composite blades results in lengthy manufacturing processes, increased weight, and a high risk of delamination during assembly. This approach incorporates additively manufactured titanium connectors, AFP The dry carbon preform is placed in the same… RTM The mold enables the simultaneous injection and curing of dissimilar materials, achieving integrated bonding and co‑curing in a single step. By eliminating secondary adhesive bonding and mechanical assembly, it reduces interfacial defects at the source, making it a benchmark solution for the engineering implementation of monolithic manufacturing of engine stator components.

Breakthrough 2 : Streamline design -  Laying down -  Molding -  Integrated Digital Twin Monitoring Link

Build CELESTIAL Interoperable Simulation Ecosystem ( ISE ), will AFP Path simulation, RTM Simulation and online 3D Seamless integration of point cloud scanning and infrared temperature data enables real-time production data to drive reduced-order modeling. ROM ) Anticipate porosity and poor wetting to enable “simulation-first” implementation. -  Process Monitoring -  A closed-loop “defect prediction” system that addresses the longstanding challenge of disconnect between traditional manufacturing simulations and shop-floor data.

Breakthrough 3 : Forming titanium - Standardized, integrated process for enhancing carbon heterojunction interfaces

Targeting 5  The challenge of interfacial debonding between titanium and epoxy composites has been addressed through a well-established, mature processing procedure: additive‑manufactured titanium parts undergo high‑temperature sulfuric acid etching to roughen the surface. + HexBond Epoxy primer for isolation and corrosion protection +  The co-cured adhesive film sandwich structure features triple‑interface reinforcement and is supported by a comprehensive interface‑performance validation protocol, addressing the industry’s longstanding challenge of bonding failure in one‑step‑formed dissimilar joints.

Breakthrough 4 Establish an industrial-grade data security framework for intelligent manufacturing of aerospace composite materials.

For cross-border joint R&D scenarios involving multi-party data interaction, based on… PRESS The guidelines establish a manufacturing data security framework, employing encrypted transmission, RBAC Tiered access permissions and regular risk audits, balancing both… HPC Simulation collaboration, along with intellectual property protection for drawings, process parameters, and inspection data, fills the gap in localized information security solutions for digital aerospace production lines.

II. Technological Innovation

Innovation 1  Multi‑process collaborative one‑step forming manufacturing line

• Preparation of titanium embedded parts: metal powder bed PBF Additive manufacturing of internal and external mounting fittings;
• Titanium interface pretreatment: 60 °C 50% Concentrated sulfuric acid etching 30 min Washing, air spraying HexBond122 The primer isolates against moisture-induced corrosion;
• AFP Preparation of the intervention system: ABB Equipped with a six-axis robot AddComposites XS Laying the head, laser activation PA12 Binder, 400 mm/s Speed weaving 40  Layer Teijin IMS65 Carbon ribbon: after laying, it undergoes vacuum pre-compaction in the oven and is manually trimmed along the narrow edges.
• In-mold composite assembly: A co-curing adhesive film is laid on the surface of the preform, and the treated titanium component is precisely positioned and placed into the steel mold. RTM Mold;
• RTM One-piece curing: 0.7 bar Low-pressure injection ensures thorough impregnation; heat up to 180 ℃, stepwise voltage increase to 6 bar Holding pressure 120min , eliminating porosity and dry spots, achieving a complete demolding in a single step. OGV Composite component.

Innovation 2  End-to-End Online Multi-Source Perception and Monitoring System

• 3D Real-time data acquisition by the laser profilometer AFP Lay down a 3D point cloud, reconstruct the digital twin of the preform, and record tow misalignment and thickness variations.
• An infrared thermal imager continuously monitors the laser‑heated temperature field, precisely controlling the binder activation range to prevent overheating‑induced degradation or low‑temperature interlayer delamination.
• Real-time upload of molding data ISE Simulation platform, driver RTM A reduced-order model for mold-filling and porosity prediction, with dynamic correction of process parameters.

Innovation 3  Interconnected Multidisciplinary Digital Ecosystem for Simulation ( ISE )

Integration of lay-up path simulation, resin infusion simulation, and structural mechanics, among others. CAE Tools, paired with high-performance computing. HPC With machine learning proxy models, standardized data streams are shared across cross‑enterprise distributed teams, supporting… OGV Multidisciplinary optimization and uncertainty quantification enable proactive verification of design manufacturability, significantly shortening the iteration cycle.

Innovation 4  Data Security Governance and Control Technology Framework for Aerospace Manufacturing

Follow ENISA 、 ECSO Industry standards, core control measures: HTTPS/SSH Encrypted transmission, key authentication, role-based RBAC Hierarchical access; classified and encrypted storage of simulation models, process parameters, and inspection data; establishment of… 3  A monthly risk monitoring and incident reporting mechanism ensures the protection of intellectual property and sensitive manufacturing data in cross-border aviation projects.

III. Application Scenarios

• Aeroengine turbofan stator components (core application scenario)

Fan rear outlet guide vanes OGV , Rectifier stators at all levels achieve significant weight reduction by replacing steel components; one-step molding eliminates assembly steps and is suitable for commercial applications. /  Mass production and prototype development of small aircraft engines.

• Aviation alloy - Composite Load-Bearing Structure

The fuselage, titanium‑embedded composite stiffening frames in the wing box, and hybrid load‑bearing components in the engine nacelle are manufactured using… AFP Prefabrication +  One step RTM Co-curing approach, reducing riveting. /  Potential for delamination at the adhesive interface.

• Small and Lightweight Stationary Blades for Gas Turbines

Low-temperature-stage guide vanes for industrial gas turbines, with a carbon‑fiber composite core. +  The metal mounting base is integrally molded, enhancing equipment efficiency and reducing the overall machine weight.

• Digital Prototyping Production Line for Aerospace Pre-Research

Transnational joint aerospace R&D project, reusable ISE An interoperable simulation ecosystem and data security framework enables multi‑institutional collaborative design, online process monitoring, and digital twin–based traceability.

• Multi-material composite support structure for space launch vehicles

Titanium‑to‑carbon‑fiber composite support structures for satellite and rocket fairings can be produced in small batches without requiring multiple sets of tooling, enabling one‑step forming and shortening the validation cycle.

IV. Summary of the Article

(1) Core Research Achievements

• Complete AFP Intervention system + 3D One-step printing of titanium parts RTM Co-cured engine OGV End-to-end engineering validation enables simultaneous molding of composite materials and metal inserts in a single mold, eliminating secondary assembly, reducing weight, improving quality, and streamlining the manufacturing process.
• Standardized “acid etching” +  Primer +  The “co-cured adhesive film” employs a triple titanium–carbon interfacial reinforcement process, effectively suppressing interfacial corrosion and debonding failure.
• Construction Design -  Laying down -  Molding -  An online monitoring and interoperable digital simulation ecosystem, driven by real-time production-line data for predictive defect detection, enables closed-loop digital manufacturing.
• A comprehensive data security solution for smart aviation manufacturing has been implemented, addressing the risks associated with the exchange of process data and simulation model intellectual property among multiple collaborating entities.

(II) Engineering Application Value

Traditional metal OGV Heavy weight, numerous defects in the composite monolithic assembly process, and high certification costs; this paper presents a complete, floor‑ready integrated manufacturing process that balances automated layup with high precision and… RTM Its low-porosity advantage makes it well-suited for lightweight upgrades in aeroengines. Moreover, it is supported by a comprehensive digitalization and data‑security framework, enabling direct application to the planning of intelligent composite‑material production lines and the preparation of prototype‑manufacturing process documentation.

(3) Current Process Limitations

• OGV Even after laying the narrow-width web, manual trimming of the fibers is still required, precluding fully automated edge trimming and thereby reducing the production line’s cycle time.
• Relying on co-curing adhesive films to enhance interfacial bonding increases material and processing costs.
• Only prototype fabrication has been completed; high- and low-temperature cycling, fatigue durability, and interface aging tests have not yet been conducted.

(IV) Future Optimization Directions

• Upgrade AFP The laying head is equipped with a dynamic laser edge‑trimming module, enabling fully automated precast production and eliminating the need for manual finishing.
• Develop a laser micro‑texturing solution for titanium surfaces to replace adhesive films, eliminating the auxiliary adhesive layer and streamlining the manufacturing process.
• Conduct wet‑heat, thermal cycling, and fatigue‑resistance durability tests to refine the lifetime database for dissimilar joints.
• Expand the process’s application scope and extend it to mass‑production lines for multi‑stage engine stators and composite hybrid structural components.

(5) Industry Insights

The optimal approach to lightweighting low-temperature stator components in aeroengines is dry fiber. AFP Prefabrication +  One step RTM Multi-material co-molding; dissimilar metals -  Integrated composite manufacturing cannot rely solely on forming processes; it must be complemented by standardized surface‑interface treatments and digital process monitoring. As digital collaborative R&D in the aerospace sector becomes more widespread, an industrial ecosystem that balances simulation interoperability with data security will become standard equipment for high‑end composite production lines, and integrated co‑curing processes are expected to gradually replace traditional discrete assembly approaches.

Image and Text Guide

Figure 1. celestial Concept. Advanced digital technologies (such as AFP and RTM ) Its increasingly widespread application in the aerospace manufacturing sector has opened up unprecedented opportunities for enhancing efficiency, precision, and sustainability. However, it has also given rise to new challenges related to data security, intellectual property protection, and trust in digital workflows. heavenly The concept of cybersecurity has been introduced to evaluate the intelligent simulation environment ( ISE ) security integration and operational capabilities; this environment supports end-to-end ( E2E ) Design ( https://doi.org/10.3390/engproc2026133047Eng. Proc. 2026,133,47 3 of 8 ) Integrated into the manufacturing process, including complex aerospace components such as engine outlet guide vanes ( OGVs ) ) production.

Figure 2.  Integrating a carbon-fiber core with a titanium alloy joint into one. OGV Schematic diagram. Image courtesy of Sweden. GKN Provided by the aerospace company

Figure 3.  Etching process for titanium joints. The geometry of this joint is determined by GKN Aerospace Sweden Company design.

Figure 4.  Use epoxy primer ( Hexcel Hexbond 122 ) Protect the surface treatment

Figure 5. OGV In AFP The manufacturing process in the production process. (a) Path planning. (b) Fiber deposition on the mold.

Figure 6：  OGV Finishing Techniques and Adhesives for Prefabricated Components P application of

Figure 7. RTM Process flow, parameters, and final results OGV Geometric structure

Figure 8.  Sky-blue digital wire. (a) An interoperable simulation ecosystem that supports the manufacturing process; (b) In AFP Process monitoring during molding is performed using a 3D profilometer and a thermal imaging camera.