Clean Sky 2 program has been designed to develop a new generation of cutting-edge technology demonstrators for the European aerospace industry. With this purpose, several concepts focused on the development of the Tail Unit of the RACER (Rapid And Cost-Efficient Rotorcraft) helicopter have been integrated, an aircraft optimized to be able to exceed 400km/h at cruising speed compared to nearly 250 km/h maximum speed of most helicopters. It also aims to reduce CO2 and NOX emissions by 20%, while its aerodynamic design helps reduce its acoustic footprint by 20% as well. The manufacturing technologies involved for the development of the tail unit considering various technologies in composite materials, and additive manufacturing (AM) as a manufacturing technology of several components belonging to the primary and secondary structure.

In this work, several success cases are presented where the Laser-Powder Bed Fusion (L-PBF) technology has been implemented for the development of the flap fittings of the vertical stabilizers in Titanium 6-Al 4-V, antenna supports and other elements in Al-Mg-Sc (Scalmalloy®). Collaborative activities have been carried out between the areas of airworthiness, structural calculation, design, and manufacturing to achieve the European milestone of flying the first built components developed by additive manufacturing technology in an AIRBUS helicopter. This work shows all the activities carried out for the qualification of manufacturing systems and the lessons learned during parts development in terms of airworthiness, design, structural integration, flight acceptance criteria, and all manufacturing considerations regarding: minimization of residual stresses during manufacturing, efficient support strategies, different machining techniques such as post-processing for the extraction of parts for achieving final tolerances of the interfaces. Concepts of improving the surface finish, protection systems against corrosion and painting, and its inspection by advanced non-destructive testing methods such as X-ray computed tomography will also be addressed.