The stiffness of the OGV is crucial as it influences the performance of the engine and includes a major load path from the core of the engine to the wing. Since each engine set has different guide vanes, designing and manufacturing OGV parts can be challenging. PMCs in aero engines interface with metallic components, and designing hybrid interfaces is challenging. The integration of a composite vane with metallic fitting parts can be achieved by metal additive manufacturing (AM) and bonding with CFRP. Titanium parts can be manufactured with Laser Beam Powder Bed Fusion (PBF-LB/M). Resin Transfer Molding (RTM) or prepreg involves infusing the vane preform with metallic fittings. Prepreg involves bonding metal parts separately. This assembly has tight geometric tolerances and strict technical specifications to ensure engine fit. The main challenge in designing and manufacturing OGV parts will be achieving the thickness variation in a short span of approximately 200mm. Defect-free structures require appropriate design and process parameters. To minimize resin concentrations and wrinkles during manufacturing, the width of the AFP tapes should form multiple drop-offs.

As part of UPBEAT, we will develop a method for identifying, quantifying, and managing uncertainties to ensure reliable design and manufacturing. Multiscale simulations of product performance, manufacturing, and assembly are necessary. Specifically, this will allow a deeper understanding of how design and manufacturing generate defects, singularities, and distortions during assembly.”