How to Build an Aircraft Tail Using One-Shot Composite Curing

A manufacturing process for creating an aircraft's rear fuselage and vertical tail as a single, integrated composite structure to reduce weight and assembly time.

What it covers

This patent describes a method for building the rear section of an airplane by combining the outer skin, internal stringers, and structural frames into a unified piece. Engineers place pre-formed composite parts, known as preforms, into specialized integration tools that act as a mold. These parts are then placed into an autoclave—a high-pressure, high-temperature oven—to 'co-cure' or harden all the components together in one single operation. This results in a stronger, lighter structure compared to traditional methods that require bolting or riveting many separate pieces together.

What it doesn't cover

• —Does not cover the manufacturing of metallic aircraft structures.
• —Does not cover the use of additive manufacturing or 3D printing for these parts.
• —Does not cover assembly methods that do not use an autoclave for co-curing.
• —Does not cover the design of the aircraft's aerodynamic shape.

The clever bit

The innovation lies in using a split integration tool that allows the frame preform to be positioned between two skin sections, enabling the entire complex geometry of the fuselage and vertical tail spar to be cured simultaneously.

Why it matters

In aerospace engineering, every gram of weight saved increases fuel efficiency and range. By moving from a multi-part assembly to a co-cured composite structure, Airbus can reduce the number of fasteners and joints required, which simplifies the supply chain and lowers the total weight of the aircraft's rear section.

Real-world examples

• 1.Airbus A350 rear fuselage sections
• 2.Modern composite aircraft empennage assemblies