PROJECT: Technological studies and developments for electric aircraft.
ACHIEVEMENT: Development of a new range of formulations to produce highly adherent, durable, and anti-icing coatings for composite and/or aluminium substrates (painted or unpainted), together with the development of a new range of formulations offering good adhesion, electrical conductivity, and electromagnetic shielding properties for composite materials and/or reinforcing materials that can be embedded into composite structures.
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The E-Flight project aims to anticipate and address the challenges that the electrification of aircraft propulsion systems will bring to the aerostructures sector by developing high value-added products, assemblies, and functional solutions required for future electrified aircraft. The electrification of propulsion systems is a key enabler of air transport decarbonisation. It not only has a direct impact on aircraft emissions but also contributes to quieter, more efficient operations while reducing maintenance costs. Achieving this requires research into key areas affecting aircraft performance and efficiency, particularly aerostructures and auxiliary systems. The integration of fully electric systems, incorporating new components, unprecedented power levels, and larger electrical architectures, will introduce new design constraints for aircraft structures.
The aerostructure of the future will be strongly influenced by the electric propulsion system and its associated energy storage system, which will need to be fully integrated into the aircraft (Battery Pack). While battery technology is already mature in sectors such as automotive, it must be adapted to meet the stringent safety requirements of aviation. In addition, auxiliary systems such as anti-icing systems will also need to be electrified and integrated into the aircraft. E-Flight is a collaborative initiative involving four Basque companies (AERNNOVA, INNOMAT, MUGAPE and ORKLI) to research and develop new materials, manufacturing technologies, and aerostructure configurations capable of integrating energy storage systems and essential electrical systems for the next generation of electric aircraft. One of the main challenges is the development of a lightweight structural Battery Pack that contributes to overall weight reduction. Another challenge is integrating propulsion systems, battery packs, and auxiliary systems (including wiring, safety components, and thermal management systems) without compromising aircraft weight or manoeuvrability.
INNOMAT's objectives in the project, carried out in collaboration with the technology centre TECNALIA, are twofold:
- Development of a new range of formulations for highly adherent, durable anti-icing coatings suitable for composite and/or aluminium substrates (painted or unpainted). Existing coating formulations and deposition technologies will be adapted to composite substrates while meeting the demanding requirements of the aeronautical industry.
- Development of a new range of formulations providing good adhesion, electrical conductivity, and electromagnetic shielding properties for composite materials and/or reinforcing materials that can be embedded into composite structures. To achieve this, polymeric coating formulations and deposition technologies capable of providing the required shielding performance will be adapted to composite substrates and aerospace requirements.
The E-FLIGHT project has been funded through the HAZITEK Business R&D Support Programme of the Basque Government. This initiative is co-funded by the Basque Government, through the Department of Economic Development, Sustainability and Environment, and by the European Union through the European Regional Development Fund (ERDF) 2021–2027.