To develop and demonstrate next-generation composite wing and flap structures, GKN Aerospace has launched a new £12 million UK research and development programme: ASPIRE. The three-year initiative officially began in May 2025 and will run through April 2028.
The project will deliver three full-scale composite wingtip variants to Ultimate Load for structural testing, offering a rare opportunity to validate advanced technologies under highly representative conditions. Each wingtip will embody a distinct set of technologies and structural philosophies:
- Variant 1: A multi-part bonded assembly based on GKN Aerospace’s existing design methodology.
- Variant 2: A quasi-isotropic, co-infused Resin Transfer Moulding (RTM) structure incorporating automated deposition, digital twin integration, and Pentaxia’s self-heated JouleTool technology.
- Variant 3: An advanced concept integrating SmaRTM processing, low-energy dry fibre forming, and non-standard fibre orientations.
Key innovations under evaluation include Carbon ThreeSixty’s stitched deltoid noodles, made from recycled carbon fibres aligned by the Lineat AFFT process, and iCOMAT’s Rapid Tow Sheared (RTS) lightweight structures. Analytical and numerical methods developed by the University of Bath are supporting the integration and validation of these technologies.
The flap demonstrator will feature a pre-preg-based manufacturing process using press-cured ribs, low-energy out-of-autoclave moulds, RTS skins (iCOMAT), and fibre-placed brackets supplied by Carbon ThreeSixty. A major milestone for the programme will be achieving Technology Readiness Level 6 (TRL6) for press-cured composite ribs — a key step toward enabling future single-aisle aircraft platforms. This work builds on GKN Aerospace’s proven capability in manufacturing the A350 flap in Munich.
“ASPIRE is a perfect example of the power of UK collaboration to drive aerospace innovation. By bringing together specialist SMEs, academic expertise, and GKN Aerospace’s industrial leadership, this programme will accelerate the development of high-rate, sustainable composite wing technologies. It strengthens our position as a trusted technology partner for future aircraft platforms and reinforces our commitment to shaping a more efficient and more sustainable aerospace industry.”
John Pritchard, President of Civil Airframe at GKN Aerospace.
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