CASE STUDIES
ASTRAL
ELCAT | FLEXCELLE | MADE SMARTER | ELASTIC | VADIS | WINGLIFT | AUTORAMP | SMARTER | CASE STUDIES
ADVANCED STRUCTURAL WING FOR ROTOCRAFT AIRFRAME
The ASTRAL project developed and demonstrated advanced design, manufacturing and testing solutions for the wings of Airbus Helicopters’ RACER rotorcraft demonstrator. Its goal was to deliver lighter, stiffer and more aerodynamically efficient wing structures that reduce fuel burn, noise and emissions while supporting Europe’s move toward greener aviation.
Launched in July 2015 and concluding in December 2020, ASTRAL formed part of the Airframe Integrated Technology Demonstrator (ITD) within the Fast Rotorcraft Innovative Aircraft Demonstrator Platform (IADP) under the Clean Sky 2 Joint Undertaking.
The project focused on the use of new digital design and simulation techniques, along with highly efficient, quality-driven and cost-effective manufacturing processes that were rigorously tested and validated to deliver the technologies needed for a world-leading rotorcraft wing.
The European aerospace sector faces intense global competition, rising customer expectations and stringent environmental regulations. Weight reduction is a key priority, as fuel burn, emissions and noise all increase in proportion to aircraft drag and lift.
ASTRAL addressed these challenges by producing a lightweight, fully optimised wing structure using high-performance ecological materials. Components were integrated to reduce assembly time and cost, while design innovations aimed to deliver measurable reductions in drag and manufacturing overheads.
The project built upon Airbus Helicopters’ RACER (Rapid and Cost-Effective Rotorcraft) platform, which aims to achieve a cruise speed of 253 knots and a 30% reduction in fuel consumption compared to conventional rotorcraft.
ASTRAL was guided by a clear set of objectives to enhance both performance and sustainability:
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Optimised design for weight reduction
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Optimised design for drag reduction and high-speed flight
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Optimised design for cost reduction
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Development of eco-friendly manufacturing methods
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Prototype assembly, tooling and validation
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Prototype testing and contribution to the Permit to Fly
The project aimed to develop a new wing architecture that would provide enhanced speed, range and agility for next-generation rotorcraft, while ensuring cost-effectiveness and industrial scalability.
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The ASTRAL team, led by Hamble Aerostructures (GE Aviation) in collaboration with the University of Nottingham and Airbus Helicopters, advanced key technologies such as Additive Manufacturing, Automated Fibre Placement (AFP), and single curing of complex composite structures for control surfaces.
These innovations supported the consortium's drive to reduce manufacturing costs, improve performance and complement high-rate aircraft production through optimised weight solutions.
In 2019, following a successful Preliminary Design Review (PDR) at Airbus Helicopters’ Donauwörth facility in Germany, the ASTRAL consortium moved into detailed design and manufacturing trials. All key technologies had reached the maturity required for this stage and were being validated ahead of component production.
By late 2019, component manufacture began, with wing delivery scheduled for the end of 2022 and first flight of RACER was achieved in 2024.
ASTRAL also demonstrated several innovative digital and automated manufacturing methods, including:
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AFP wing skin panels
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Novel assembly fixtures and adaptive clamping systems
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Automated sealant application and nut plate installation
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Collaborative robotics for dexterous processes
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Virtual reality applications for assembly planning
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ASTRAL plays a central role in achieving the ACARE environmental targets by contributing to substantial reductions in aircraft weight, fuel consumption and emissions. The technologies and methods developed have strengthened the competitiveness of the European aerospace industry by demonstrating how advanced digital manufacturing can support sustainable, high-performance aircraft design.
The project’s achievements continue to influence future research and industrial programmes across the rotorcraft and fixed-wing sectors.
The collaboration with the University of Nottingham has been pivotal to the digital industrial assembly and integration success of the ASTRAL wings, nacelles and flaps structures. Co-development of model-based engineering and simulation techniques in the Omnifactory synthetic environment has been a fundamental advancement in our technology roadmap and improvement in our industrial footprint.
Philip Scott, Head of Design, Research & Development,
Hamble Aerostructures
