CfP03 Call Text 133
3. Major deliverables/ Milestones and schedule (estimate)
Deliverables
Ref. No. Title – Description Type Due Date
D 1 Concept for Canopy (material, structure, etc.) Doc T+6
D 2 Detailed drawings Doc T+16
D 3 Canopy (not-flightworthy hardware) incl. maintenance doors, fairings for mock up
HW T+24
D 4 Canopy (flightworthy hardware) incl. maintenance doors, fairings for FRC demonstrator
HW T+22
D 5 Test and “Permit to Fly” documentation Doc T+32
D 6 Support to Flight Test Campaign - T+41
Milestones (when appropriate)
Ref. No. Title – Description Type Due Date
M 1 PDR MS T+6
M 2 CDR MS T+18
M 3 Flight test survey MS T+50
4. Special skills, Capabilities, Certification expected from the Applicant(s)
The Topic Manager is the responsible in front of the airworthiness agency, and it is therefore mandatory that the Topic Manager will be supported by the Partner with respect to all certification related activities in relation with the Canopy. Therefore the Partner has to provide all documentation necessary to achieve “Permit to Fly” and take action allowing this goal to be reached:
Providing material data which are required to achieve a “Permit to Fly”;
Using material, processes, tools, calculation tools etc. which are commonly accepted in the aeronautic industry and certification authorities;
Harmonization of calculation processes/tools with the Topic Manager; Acting interactive with the Topic Manager at any state of work;
Giving access to the production and test sites;
Performing the updates of documentation in case of in-sufficient documentation for authorities;
Ensure TRL level 4 is reached for each system/technology upon project start (Q2 2016). Should this condition not be met, the Partner has to provide a mitigation plan enabling to reach the target of TRL 6 at the end of demonstration.
CfP03 Call Text 134 The target is obtained the lowest weight as possible for the proposed component compliant with technical requirements and compatible with a serial aeronautical production.
The applicant(s) shall provide an estimated maximum weight of its proposed component. This value will be updated before T0 regarding the design data available at this time, the difference with the weight provided with the offer shall be substantiated and the new weight figure will have to be agreed with the Topic Manager.
For the PDR, the Partner shall a detailed weight breakdown of the component in accordance with the technology, the technical requirement and the interfaces agreed with the leader. The difference with the weight agreed at T0 will be substantiated and submitted to the agreement of the Topic Manager. For the CDR, the Partner shall provide an update of the weight breakdown with a substantiation of the difference with PDR version. If an update of the overall weight is necessary, it will be submitted to the agreement of the Topic Manager.
The components for the flying demo will be delivered with a weight record sheet; deviation with the maximum weight agreed during CDR will be substantiated.
At the end of the contract, the Partner shall provide a weight estimation of the component for a production part in accordance with the lessons learned during the development.
Recurring cost estimation:
The target is to obtain the optimum between the level of performances of the fast rotorcraft and the cost of the potential product.
For the PDR, the Partner will provide an estimation of the recurring cost of the component on the basis of the assumptions given by the Topic Manager. An up-date will be provided for CDR and at the end of the demonstration phase.
Data management:
The Topic Manager will use the following tools for drawing and data management: CATIA V5 R21
VPM Windchill
The Topic manager will provide interface drawings and 3D model loft in CATIA V5 R21.
The Partner will provide detailed 3D models for digital mock-up in CATIA V5 R21 and he will support the Topic Manager for the interface definition.
The data necessary for configuration management have to be provided in a format compatible with VPM and Windchill tool.
Eco-design
Capacity of performing Life Cycle Analysis (LCA) to define environmental impact of technologies (energy, VOC, waste, etc) is required from the Partner.
This approach will be integrated during design & manufacturing phases. The Topic Manager will be able support LCA approach (Methodologies training or pilot cases).
CfP03 Call Text 135
Special Skills
Abbreviations: (M) for Mandatory; (A) for Appreciated (with respect to the chosen manufacturing process)
- Experience in design and manufacturing of structures in non-conventional and conventional composite materials (thermoset and thermoplastic) and innovative metallic components as well as hybrid structural concepts (M)
- Design, analysis and configuration management tools of the aeronautical industry (i.e. CATIA v5 release 21, NASTRAN, VPM, Windchill, …) (M)
- Competence in management of complex projects of research and manufacturing technologies. (M)
- Experience with TRL Reviews or equivalent technology readiness assessment techniques in research and manufacturing projects for aeronautical industry. (M)
- Proven experience in collaborating with reference aeronautical companies with industrial air vehicle developments with “in – flight” components experience. (M)
- Capacity to support documentation and means of compliance to achieve experimental prototype “Permit to Fly” with Airworthiness Authorities (i.e. EASA, FAA and any others which may apply). (M)
- Capacity to specify material and structural tests along the design and manufacturing phases of aeronautical components, including: material screening, panel type tests and instrumentation. (M)
- Capacity to perform structural and functional tests of aeronautical components: test preparation and analysis of results (M)
- Capacity to repair “in-shop” components due to manufacturing deviations. (M)
- Capacity of performing Life Cycle Analysis (LCA) and Life Cycle Cost Analysis (LCCA) of materials and structures. (A)
- Capacity of evaluating design solutions and results along the project with respect to Eco- design rules and requirements. (A)
- Design Organization Approval (DOA). (M) - Product Organization Approvals (POA). (M)
- Quality System international standards (i.e. EN 9100:2009/ ISO 9001:2008/ ISO 14001:2004) - Qualification as Material and Ground Testing Laboratory of reference aeronautical companies
(i.e. ISO 17025 and Nadcap). (M)
- Technologies for composite manufacturing with OoA processes: e.g. RTM, Infusion, SQRTM Thermoforming, Roll-forming (M)
- Mechanical processes, in both composite material and metallic. Hybrid joints (CFRP + Metal) Manual composite manufacturing: hand lay-up (M)
- Mechanical processes for sheet metal manufacturing: e.g. AM, Hydroforming, FSW, SPF (M) - Tooling design and manufacturing for composite components. (M)
- Advanced Non Destructive Inspection (NDI) and components inspection to support new processes in the frame of an experimental Permit to Fly objective. (M)
CfP03 Call Text 136 Material and Processes
In order to reach the main goals of the project two major aspects have to be considered for materials and processes, namely: maturity and safety for the project.
Because of the ambitious plan to develop a flying prototype in a short time frame, the manufacturing technology of the partner must be on a high maturity level (TRL4) in order to be able to safely reach the required technology readiness for the flying demonstrator.
To secure this condition, the core partner will have to demonstrate the technology readiness for his proposed materials and process and manufacturing technology with a TRL review, to be held together with the Topic Manager.
The TRL review must be held within one year after beginning of the project and must confirm a maturity of TRL5 or at least TRL4 if a solid action plan to reach TRL5 within the scope of one further year and finally meet the TRL target for the demonstrator is validated and accepted by the Topic Manager. Furthermore, since the schedule of the project and the budgetary framework don’t allow for larger unanticipated changes in the middle of the project, it is required that at the start of activities the partner demonstrates his capability to develop and manufacture the required items with a baseline technology) which will be a back-up solution if the new technology to be introduced proves to be too challenging.
This back-up plan, which shall secure the meeting of the project goals shall also be agreed between TM and the Partner within half a year after start of the activities and approved by the JU.
Furthermore the M&P activities shall support the safe inclusion of the partner technology into the complete H/C.
Certification:
Design Organization Approval (DOA). Product Organization Approvals (POA).
Quality System international standards (i.e. EN 9100:2009/ ISO 9001:2008/ ISO 14001:2004) Qualification as Material and Ground Testing Laboratory of reference aeronautical
companies (i.e. ISO 17025 and Nadcap).
CfP03 Call Text 137