The CAELESTIS project aims to promote the development and design of innovative aircraft and engine structures through an integrated ecosystem of simulations and digital tools, enabling synergy across all stages of the manufacturing process. The component selected was an Outlet Guide Vane (OGV), a static engine part composed of a central composite section and titanium inserts at both ends, joined in a single manufacturing step. A detailed investigation of the joints between these materials was carried out using surface treatments of different natures to evaluate properties that directly influence the final joint quality. Optical analysis techniques were employed to characterize the morphology, roughness and surface free energy (SFE), complemented by mechanical tests to determine the adhesion and shear strength. All specimens were manufactured using the Resin Transfer Molding (RTM) “one-shot” process.

The combination of the dry fiber AFP preforming process and RTM injection process brings new possibilities with regard to automation, high-quality manufacturing, and high-performance characteristics for out-of-autoclave composite manufacturing, particularly in aerospace industry. This paper describes the manufacturing of an aircraft engine Outlet Guide Vane (OGV), made with a dry carbon fiber preform manufactured with Automated Fiber Placement (AFP) and co-injected, co-cured, and co-bonded with titanium fittings through the Resin Transfer Molding (RTM) Process. The details of the assembly process and necessary steps are described. Parts of the digitalization process behind the manufacturing are described, including information about integrated sensors and data management.

Graphene is a novel material that can bring several advantages in the composite materials manufacturing field, such as improved electrical and thermal properties, and high performance. In particular, functionalizing current composite materials can bring advantages in the aerospace field in thermal management for electric aircraft engines. This paper studies the addition of graphene particles into carbon fiber composites manufactured by the Resin Transfer Molding Process (RTM). Thermal and mechanical properties are evaluated and compared with a conventional composite laminate. Major improvements were achieved on the thermal behavior of the composite material while maintaining general properties, but in particular, the addition of graphene had a negative impact on transverse tensile and mode II fracture toughness due to agglomerates present in the fiber–resin interface.