NEUTRON Project Yields Composite Helicopter Engine Deck With CMC Firewall

At ILA Berlin 2026, Airbus Helicopters (Donauwörth, Germany), as project lead of the NEUTRON research initiative (2022-2025), presented a full-scale composite engine deck demonstrator developed with the DLR Institute of Structures and Design (Stuttgart and Augsburg). Funded by the German Federal Ministry for Economic Affairs and Energy, the project addresses weight and thermal challenges introduced by next-generation helicopter propulsion systems.

To replace traditional metallic decks, Airbus Helicopters engineered a novel multi-material concept that decouples structural load paths from thermal insulation. While primary propulsion loads are transmitted via three precision titanium fittings, a co-cured ceramic matrix composite (CMC) firewall isolates the carbon fiber-reinforced polymer (CFRP) airframe. This integrated CMC barrier withstands continuous operating temperatures up to 1100°C, fulfilling strict engine-bay fire protection and certification standards.

Crucially, the entire assembly employs a fastener-free design methodology. Eliminating mechanical fasteners reduces weight, minimizes localized stress concentrations and streamlines manufacturing. Beyond the engine deck, Airbus Helicopters evaluated structural layouts to integrate high-voltage battery modules, satisfying crashworthiness and energy-absorption requirements under severe impact conditions.

To productionize Airbus Helicopters’ design, the DLR developed a semi-automated manufacturing framework featuring four key technological bricks: (i) A robotic pick-and-place system with optical contour detection and in-line fiber-angle monitoring; (ii) an adaptive diaphragm-preforming station for net-shape consolidation; (iii) the “Shepard” data framework for digital twin quality tracking; (iv) and an out-of-oven (OOO) interdiffusion-based joining process that structurally bonds cured CFRP subcomponents without secondary vacuum bagging.

The success of the NEUTRON demonstrator highlights the effective system integration spearheaded by Airbus Helicopters. The core consortium combined the lead partner’s structural architecture with specialized research from project partners: DLR (process automation and OOO joining), Fraunhofer IGCV (composite processing), Fraunhofer ISC (advanced CMC material formulations) and the University of Stuttgart (acoustic and structural dynamics).