Application Technology

The maiden flight of the HYFLY H167 hydrogen fuel cell propulsion system was a full success and aboard the test aircraft was RAMPF’s high performance epoxy resin RAKU^® TOOL EI-2511/EH-2990, which was used to manufacture the extremely lightweight and robust battery box housing. 

Through a partnership with aircraft engineering provider Kasaero GmbH, RAMPF has developed and manufactured a high performance battery box housing for HYFLY H167, which includesa hydrogen fuel cell propulsion system. The housing of the test aircraft’s battery box was made from glass fibre composite – with the housing’s frame and cover engineered for minimal weight, maximum strength and durability. This design ensures the housing can withstand the high mechanical, thermal and vibrational loading that the battery box would be exposed to.

Composite parts were produced via Vacuum Assisted Resin Transfer Moulding (VARTM), with the moulds for the lay-up tools directly manufactured from Kasaero’s CAD data. The RAKU^® TOOL EI-2511/EH-2990 epoxy resin was ultimately chosen to fix the final parts on the mould. RAMPF’s epoxy resin is a flame retardant structural resin that exhibits low viscosity at low processing temperatures and also fulfils 12 second and 60 second vertical burn tests, as well as the oil burner test for firewalls, engine nacelle components and cargo liners. 

RAMPF also completed the final assembly of the battery box housing, thanks to its capabilities in composite design. Max Schultes, CTO at RAMPF Group, explains: “RAMPF’s comprehensive material and engineering portfolio enables us to deliver high-quality, scalable solutions for advanced lightweight composites quickly and efficiently. Prototypes are manufactured within weeks of the design stage and with up to 30% cost savings compared to more traditional solutions.”