History

History FITS AIR System

• Schreiner Composites: A joint venture between KLM and Schreiner Airways led to the development of FITS AIR using MC (Methylene Chloride), producing 1 m² panels in cooperation with what is now Polytec Roosendaal, NL.
• Machinery & Investments: Several part-manufacturing machines were developed for edge finishing, folding, injection molding of inserts, and 3D thermoforming. Total investment reached DFL 15,000,000. A contract was signed with Boeing, but due to the oil crisis and the use of MC as a blowing agent, the venture went bankrupt.
• TU Delft Research: A PhD candidate at TU Delft shifted the blowing agent for FITS AIR from MC to Acetone. FITS further developed the in-situ foaming process at a laboratory level, subjecting FITS AIR to extensive mechanical and flammability testing.
• Airbus & Tier 1 Testing: Airbus tested the panels for mechanical and flammability properties, and FITS AIR fulfilled all requirements for aircraft interiors. A Tier 1 aircraft interior supplier purchased 40 FITS AIR panels (50x30 cm) for testing and prototype manufacturing of oxygen system lids. FITS AIR was proven to deliver a weight saving of 70% compared to current technology (saving 50 kg on an Airbus A350). The Tier 1 supplier subsequently introduced FITS AIR to other divisions.
• Upscaling Challenges: Voestalpine Polynorm (now Polytec) committed as a partner to manufacture 4x5 ft FITS AIR panels and upscale production. However, the Tier 1 supplier did not commit to an investment of €100,000.
• Boeing Orders: Boeing ordered test panels for mechanical and flammability testing, yielding excellent results.
• FITS Trolley: Technical discussions and workshops resulted in a FITS Trolley design weighing just 10 kg, featuring insulation and full recyclability.
• SMTC Pilot panel manufacturing:Together with SMTC, France (Dynatech) 200 panels (4x5 ft) were manufactured at the University of Bayreuth, showing very high mechanical properties.
• SMTC Lawsuit SMTC attempted to steal the technology, resulting in a three-year lawsuit at the Dutch court in The Hague. FITS won the lawsuit, and its patent withstood the dispute. Total investment: €5 million.
• Luggage Bins: FITS designed a luggage bin for an aircraft Tier 1 supplier. The design by FITS and stress analysis by ADSE (Hoofddorp) resulted in a cheaper bin and a weight saving of ±1 kg per bin. By the way: All Airbus luggage bins produced annually could be manufactured with FITS AIR using just 10 machines, with a manufacturing time of 2 hours per bin, easily keeping up with increasing aircraft production.
• Highest loaded interior panel: A presentation to an aircraft manufacturer sparked great interest in an FITS AIR application for the highest loaded interior sandwich panel in an AC, due to lower weight and significantly lower costs. This followed a technical deep dive and mechanical testing by the AC stress department.
• Disruption & Recovery: Discussions with potential suppliers were disrupted by Covid-19. Post-Covid, significant interest returned regarding recyclable interiors.
• Market Adoption: Several attempts were made to partner with Tier 1 or Tier 2 suppliers. However, despite significant commitment from these suppliers, aircraft manufacturers failed to support the initiative.
• Supply Chain: FITS found a second source for the basic polymer PEI (Polyetherimide) from SABIC through Gharda Chemicals in India, which is required for aircraft production.
• Crush Energy Tests: Crash energy absorption tests with an aircraft manufacturer proved that FITS AIR significantly outperforms all existing sandwich panels for aircraft interiors and also showing much lower damage.
• Patent Protection: FITS AIR panel production (TRL 5/6) is protected by 4 worldwide granted patents. Detailed manufacturing reports are available for luggage bins, sidewalls, galleys, dado panels, and oxygen system lids.

 

The FITS BASE System

FITS BASE patents were applied for after the process was initially validated on a panel size of 4x6 cm.
Recently, investigations into the in-situ foaming of FITS BASE panels were performed at a size of 24x32 cm in cooperation with a PP supplier and a Tier 1 automotive supplier. This included research into the extrusion of foamable film with non-reacted CBA.
Significant progress was made regarding the extrusion of these films and the in-situ foaming of FITS BASE panels. However, stable production of FITS BASE panels could not yet be established. While our laboratory installation operated successfully, more fundamental research is required to determine if this process is commercially viable.
FITS has paused this research because it currently lacks the financial means to pursue this opportunity, which would require an estimated 6 to12 months of further development. FITS BASE panel production (TRL 2/3) is protected by 5 worldwide granted patents.