JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 48

SOLUTlONS defence
ergonomics, the design of the
cockpit escape capsule, and the
man/machine interfaces. Many
factors weigh heavily on the cost
of developing a plane intended
for military use.
In this context, Boeing Australia
and the Australian government
were in close contact in order
to arm the Australian Air Force
with this new disruptive weapon.
Starting from a blank slate, the
Loyal Wingman programme aims
to equip fighter pilots on mission
with three AI-controlled drones
acting as body guards. The pilot is
thus able to concentrate solely on
his flight plan without worrying
about potential collisions with
his escort, as the artificial intelligence pays particular attention
to this aspect. These independent
drones do not require control
from the ground and in fact rid
the process of all the micro-tasks
involved with a traditional drone.
Though control can be taken
back at any time when needed,
personnel on the ground is free
to focus more fully on the overall
tactical strategy of the mission at
hand. In this way, the UAV developed by Boeing differs from others in its class requiring human
intervention from the ground in
tandem with the drone in action,
such as the MQ-9 Reaper used by
the US Air Force (USAF). All of
these elements come together to
produce what Boeing Australia
sums up as a concept which "enables flexible third-party autonomous behaviours", hence the title
"Loyal Wingman".
A project that's just
as ambitious as it is historic
The Loyal Wingman is an 11.7m
long UAV with a flight range of
3,700 kilometres. Its engines enable it to reach subsonic cruising
speeds, an essential condition for
keeping up with fighter planes

48

The swarm systems are expected to be ready by the end of this year ©Boeing Australia

during a mission. Made of advanced composite materials, the
UAV proudly features "the largest
resin-infused single piece" ever
produced by Boeing. The wings
are composed of only two composite parts (top and bottom)
produced as a result of advances made by the group during
the creation of the Boeing 787
"Dreamliner" (advanced out of
kiln resin-infusion process). This
contributes to reducing production costs and processes.
The Loyal Wingman is also customisable, thanks to a nose section that can be switched out in
less than an hour on the ground
(snap on-snap off system). With
a capacity of 1,500 litres the available space means the device can
be configured for various equipment, the details on which have
not yet been made public by Boeing. Military experts and consultants nonetheless suggest that it
would essentially be for tracking
and sensor systems, or weaponry.
With a group of thirty-five Australian companies as partners, like
RUAG Australia, BAE Systems,
the project has made remarkable
progress. Starting from a blank
page, the first rendering was
ready only 14 months after the

programme began. Conducted
entirely in Australia, the Boeing
Air Teaming System is the fruit of
ambitious cooperation between
Boeing Australia and the Australian Defence Ministry, carried out
with financial backing (40 million AUD dollars in investments)
from the Australian government.
"The Loyal Wingman programme
will give us a depth in Australian industry that will allow us to be more
self-reliant," declared Australian
Prime Minister Scott Morisson. It
is also the first time that a project
of this size has been carried out
by Boeing outside of the United
States.
The project is also ambitious for
its means of production. The
teams set up full digital concepts
of the flying equipment, which
enabled a digital twin to be created. This model then served as
a sand box environment for engineers, who subjected each element to physical stresses through
simulation software. They were
then able to observe its responses
and behaviours, saving precious
time on the physical test phases.
The time and money saved by not
having to create intermediate prototypes is appreciable. The teams
involved were thus able to deliver
a device closer to a demonstrator

jec composites magazine / N°137 November - December 2020

than a prototype, in the strictest
sense of the word. With this in
mind, the automated production
lines considered for fulfilment of
Loyal Wingman at full ramp-up
were implemented at a very early
stage in the roll-out of the project.
By proceeding in this manner,
Boeing Australia has been able
to test and validate the concepts
chosen all throughout the development process, by projecting
itself into the conditions of largescale production from the very
start.
A new, affordable offer
While it is currently focusing
on the Australian territory and
governmental
organisations,
Boeing's plan is based on the definition of a new need: assisting
existing aircraft during airborne
operations. As the Australian
Royal Air Force (RAAF) purchases from the American F-35
aircraft programme, its fleet is
technically comparable to the
USAF planes. This is no small
detail. With these craft as the lead
for teaming the Loyal Wingman
UAV, the company is assured of
the technical interoperability necessary for commercialization to
other global players. Designed to
adapt easily to various technical
constraints, and in particular the



JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020

Cover
Edito
“We can change the way we envision global shipping overall”
Contents
NEWS
In brief
Agenda
BUSINESS
Human ressources - Skills requirements in the composite materials sector – the French example
Startup - Make lightness and performance affordable without compromising the environment
Offshore - GWEC: Asia Pacific to become the largest offshore wind market by 2030
MANUFACTURING
Additive manufacturing - The METHOD platform expands to support more materials,applications, and markets
Automation - One-shot manufacturing of cylindrical lattice structures for satellite applications
Recycling - World’s first fully-recycled thermoplastic composite application in aerospace
Additive molding - From large-scale continuous thermoplastic composites to mass production
FEATURE AUTOMOTIVE - Is it possible to do better?
FRP - Fully coupled processstructure analysis for automotive center floor panel
Honeycomb - Composite materials for lighter vehicles
Additive manufacturing - Transforming composite production processes with FDM additive manufacturing
EV - All-composite EV wheel moves to next development phase with pilot production
Security - The world’s fastest armoured car
Natural fibre - Sustainable composite solution for new Toyota LQ concept car
SOLUTIONS
Defence - Drones as wingmen
City - Composites for tomorrow’s cities
Maintenance - Degradation mechanism and maintenance of GFRP hydrochloric acid storage tanks
TECHNOLOGY
Bonding - Adhesion properties of bonded composite-to-aluminium joints using peel tests
Inside the lab - The University of Southern Queensland - Centre for Future Materials
Method - Weight and cost reduction with double-double laminates
Index
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JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Cover
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 2
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Edito
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - “We can change the way we envision global shipping overall”
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 5
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Contents
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 7
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - In brief
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 9
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Agenda
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Human ressources - Skills requirements in the composite materials sector – the French example
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 12
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 13
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Startup - Make lightness and performance affordable without compromising the environment
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 15
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 16
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Offshore - GWEC: Asia Pacific to become the largest offshore wind market by 2030
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 18
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive manufacturing - The METHOD platform expands to support more materials,applications, and markets
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 20
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Automation - One-shot manufacturing of cylindrical lattice structures for satellite applications
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 22
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 23
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Recycling - World’s first fully-recycled thermoplastic composite application in aerospace
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 25
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 26
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive molding - From large-scale continuous thermoplastic composites to mass production
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 28
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 29
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - FRP - Fully coupled processstructure analysis for automotive center floor panel
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 31
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 32
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 33
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Honeycomb - Composite materials for lighter vehicles
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 35
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 36
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive manufacturing - Transforming composite production processes with FDM additive manufacturing
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 38
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - EV - All-composite EV wheel moves to next development phase with pilot production
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 40
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Security - The world’s fastest armoured car
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 42
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 43
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Natural fibre - Sustainable composite solution for new Toyota LQ concept car
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 45
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 46
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Defence - Drones as wingmen
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 48
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 49
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - City - Composites for tomorrow’s cities
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 51
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Maintenance - Degradation mechanism and maintenance of GFRP hydrochloric acid storage tanks
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 53
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Bonding - Adhesion properties of bonded composite-to-aluminium joints using peel tests
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 55
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 56
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 57
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 58
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 59
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 60
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 61
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Inside the lab - The University of Southern Queensland - Centre for Future Materials
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 63
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Method - Weight and cost reduction with double-double laminates
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 65
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 67
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 68
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