7. Flap Design Case Study

The wing leading edge and trailing edge high lift system is essential for the low speed characteristics of the aircraft. Advanced CFRP technology can contribute to cost and weight savings on aircraft level as well as to improved low speed performance and added product value for the aircraft operator. In this case study, different CFRP flap design schemes and manufacturing technologies are discussed, pointing out the interdependence of CFRP material, design, manufacturing process and resulting part properties. Starting with the description of the reference flap design and the most relevant design targets, new solutions such as multi-spar and sandwich designs are characterised with their advantages and shortfalls. Advanced thermoset solutions (based on prepreg and resin infusion technology) and thermoplastic solutions (based on the tape laying technology) are included. Material and manufacturing as well as strength and stiffness aspects related to aerodynamic performance are analysed. In addition, wing integration challenges linked to new design schemes are discussed.