IMDEA Materials Assists Aircraft Sensor Technology

Imdea Materials Institute Developing Smart Sensors for Aerospace Composites IMDEA Materials Institute is playing a significant role in developing next-generation aircraft sensor technology that will enable real-time monitoring of aircraft fuselage components during flight. These smart sensors, designed to be embedded within components, will deliver substantial benefits to the airline industry in both cost and safety terms in the coming years. One of IMDEA Materials' roles in this international research consortium is to conduct the advanced simulation and experimental work required to develop sensor technology and to create high-fidelity virtual models known as "digital twins." Moisés Zarzoso, researcher at IMDEA Materials, explained: "They are called digital twins because they are highly accurate digital models that replicate the physical part or component in the aircraft in real time, updated throughout its entire lifecycle. Through the embedded sensor, the physical component can communicate directly with engineers on the ground. For example, if a component is struck by hail during flight, any information about potential damage to the part will be recorded by that sensor and then automatically sent to its digital twin."

Analyzing Risk

Zarzoso added: "Using this information, the simulations we are developing will be able to analyze the risk that a potential impact could pose to the structural integrity of the component and determine its remaining service life." This research is being conducted through the Institute's Structural Composites group, led by Professor Carlos González. The role of simulation and modeling work in developing such cutting-edge sensors allows researchers to push the boundaries of material characterization. Most importantly, technology developed through the DOMMINIO project will not only enable real-time monitoring. Advanced 3D printing techniques will also be applied in the production of carbon nanotube (CNT) fibers to embed the sensor within the component during manufacturing. This means a significant reduction in the amount of electrical wiring required to power current-generation aircraft sensors.

Environmentally Friendly and More Cost-Effective

A combination of lighter and more energy-efficient sensors, together with reduced wiring, will make aircraft more fuel-efficient and thus enable operators to fly in a more environmentally friendly and cost-effective manner. The DOMMINIO project also includes the Multifunctional Nanocomposites group at IMDEA Materials, led by Dr. Juan Jose Vilatela, which is responsible for developing the CNT sensor and conducting experimental analysis of its piezoresistive properties when embedded in the component. Zarzoso stated: "The sensors are designed to be made from these fibers, which are incredibly light compared to current materials and also consume very little energy. They are also 3D printable and, given that they are CNT fibers, they can be easily embedded in a component made from conventional carbon fiber, a very common material in aircraft manufacturing." Zarzoso also noted that this will allow airlines to adopt more efficient and effective maintenance programs. Zarzoso said: "Aircraft maintenance is scheduled; after a predetermined number of flight hours, you must ground the aircraft to inspect various parts and components." He continued: "If you can find a new way to design and manufacture these aircraft, this could give you real-time information about the structural health of the fuselage from the sensors, improving the maintenance process. This will provide significant time and cost savings for airlines while maintaining compliance with rigorous safety standards," he concluded. Source