A new era
Thermal requirements in aerospace are evolving: thermoplastic composite processing, complex 3D parts and faster production rates. Heating solutions must guarantee precision, uniformity and real-time control.
Thermal challenges for
aerospace
High
Precision
Heating very quickly, at very high temperature, with perfect uniformity across each area of the part.
Complexity &
Adaptability
3D geometries, variable thicknesses, composite materials: processes must adapt continuously.
Faster production rates
The transition to thermoplastics requires shorter cycles with no compromise on quality.
Safety
and Traceability
Each cycle must be controlled, recorded and reproducible, with full traceability for processes subject to very stringent quality requirements.
Sopara’s thermal response
Thermal solutions
designed for aerospace
Applications for aerospace: heating and forming solutions
From cabin interiors (seat structures) to major structural components (doors, fuselage), increasingly large and demanding.
Testimonials
and feedback
Client case 1
Aerospace manufacturer
The industrial challenge
Industrializing up to 300,000 parts/year (1 part/3 min) in 3D thermoplastic composites with variable thicknesses, making conventional technologies obsolete: non-compacted parts, heterogeneous temperatures between layers, insufficient mechanical performance.
The technological achievement
Deployment of IRM HP Aero V5 (unique worldwide patent):
- direct heating of 3D preforms
- heaters adapted to shapes
- thermal pixelization up to 132 zones/m², independently controlled
- elimination of cold zones
The impact
3D
Controlled heating of complex shapes
100%
Guaranteed mechanical performance
100%
Active heater zone
Multi-zone
High-precision thermal control
Client case 2
Aerospace manufacturer
The industrial challenge
Industrializing carbon thermoplastic composites with fast cycles and no mechanical compromise, challenging conventional technologies with high thermal inertia (400–450°C in 20 minutes), which limit production rates.
The technological achievement
Adoption of fast-response medium-wave infrared:
- low thermal inertia
- direct transfer to the material
- 10 years of development for thermal uniformity among the highest in the world.
The impact
Divided by 4
Energy per part
±10°C at 450°C
Thermal precision
5–10 min
Cycle time (vs 20 min)
Credibility & industrial
deployment
Industrial ecosystem
Collaboration with OEMs and specialized laboratories (ESTIA / Compositadour). Deployment with major manufacturers and equipment suppliers (Airbus, Daher, Duqueine, etc.), on industrial projects at international scale.
Knowledge transfer & expertise
Training for methods engineers, R&D and technical teams. Expert speaker at the Composite Academy.
Project rigor & methodology
Structured approach: audit, testing, pilots, industrialization, training, predictive maintenance. ISO 9001 certification, progressive process validation and on-site adjustments.
Frequently asked questions
Aerospace processes impose high requirements in terms of stability, repeatability and process safety. Sopara is ISO 9001 certified and designs solutions capable of heating high-performance thermoplastic composites up to 450°C with uniformity of around ±10°C, with validations under way to reach ±5°C. Processes are qualified by customers according to their own standards, with a progressive approach enabling the specific constraints of each aerospace programme to be integrated.
Sopara solutions can be integrated both into lines designed by integrators and directly at industrial sites. The approach is based on a detailed understanding of the customer’s thermal processes: audit of existing installations, analysis of material and cycle constraints, then laboratory testing and pilot phases. This approach makes it possible to adapt the solution precisely to the industrial need and secure its integration without disrupting existing processes.
The gains mainly concern cycle times and productivity. Where legacy technologies could heat composite parts to 400–450°C in around 20 minutes, Sopara infrared solutions make it possible to fit into overall cycles of 5 to 10 minutes, in line with the requirements of thermoplastic composites. These performances make it possible to achieve high industrial production rates, with output reaching up to one part every 3 minutes on certain lines.
Thermal uniformity is a critical issue for the mechanical performance of composite parts. Sopara has developed infrared heaters with very high uniformity, among the most efficient in the world, making it possible to greatly reduce cold zones and use up to 100% of the usable surface area. This innovation, resulting from several years of development and integrated into patented solutions, makes it possible to achieve temperature precision of ±10°C at 450°C, with targets of ±5°C, guaranteeing controlled thermal quality even on critical parts.
Sopara infrared ovens rely on direct energy transfer to the material, without unnecessarily heating the surrounding air, which greatly limits energy losses. Audits carried out on industrial installations show that Sopara infrared ovens make it possible to divide cycle times and energy consumption per part by 4, compared with legacy technologies.
Sopara technologies are already deployed on aerospace industrial lines in Europe and internationally. They are based on more than 20 years of testing and development on high-performance composites, with continuous improvements leading to patented solutions. Depending on the application, projects range from fully industrialized processes to more advanced innovation phases, integrated into developments for future aerospace programmes.
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