TAVieDa – Integrated Product and Process Development for the Next Generation of Aircraft Doors

New Material and Production Concept Dramatically Reduces Aircraft Door Manufacturing Time

The manufacturing of passenger aircraft doors is still largely manual work. The highly precise assembly of the door structure is particularly time‑consuming. In traditional designs that combine aluminum, titanium, and thermoset materials, substantial effort must be devoted to corrosion protection. In contrast, using thermoplastic carbon fiber composites (CFRP), which can be welded together without layer separation, significantly accelerates the process.

As part of the TAVieDa aviation research program, a novel modular aircraft door and a corresponding assembly concept were developed simultaneously. The resulting assembly‑optimized component design, along with the developed production equipment, enables fully automated assembly of six door variants on a single system. The combination of manufacturing‑oriented design and efficient automation promises assembly times of just four hours per door—a 96 percent reduction compared to the current 110 hours. In addition, the choice of materials and design leads to significant weight savings. The early, integrated development of both the component and the manufacturing solution enables substantial cost savings across all areas.

Virtual Development of Automated Door Assembly Based on an Autonomous Robotic Cell

This partial commonality across variants was used to develop joining and clamping tools that can be applied to all door versions. Joining tools and components were developed simultaneously and iteratively optimized for optimal accessibility and joinability, with virtual verification already carried out at this stage using kinematic simulation. As a result, different aircraft door types can be assembled on a single production line, ensuring optimal utilization of the system. Adaptive positioning of clamping and joining tools, along with the use of sliding interfaces in certain components, allows robot-based positioning for the majority of parts, reducing the complexity of the tooling.

Based on an evaluated assembly sequence, a complete digital layout for assembly simulation was defined. Specially designed fixtures, robots, and production equipment were combined into a multi-cell assembly line within a virtual environment using 3D simulation software. Robot operations—such as component feeding, welding processes, tool changes, and part transfer—were simulated in detail. Logistics were also incorporated by integrating autonomous guided vehicles for component supply and transporting finished door structures, with route planning and time requirements analyzed.

The virtual simulation of the entire system enabled further optimization. The number and positioning of robots were adjusted to approach optimal material flow between stations and to ensure smooth transfer of door subassemblies. With the optimized system design, an assembly time of four hours per aircraft door was calculated within the virtual environment. Under continuous operation, this allows for the production of up to 10 aircraft doors per day in a two-shift system.