A Modular Assembly Concept for Large-Volume CFRP Hydrogen Tanks for Passenger Aircraft

This paper presents a novel modular assembly concept for large-volume Carbon Fiber Reinforced Plastics (CFRP) hydrogen tanks, supporting the aviation sector’s transitiontoward sustainable propulsion. Adhering to VDI 2221 and 2222 design methodologies,four assembly concepts were developed and then evaluated by Airbus, FFT, and FraunhoferIFAM, to determine the best fi for industrial application. The "Modular Assembly Systemon Linear Axes" was identifie as the best solution, characterized by superior processrobustness and efficienc. Utilizing dual linear axes for precise component handling androbotic guidance, this concept ensures structural integrity during joining while offeringscalability and seamless integration into existing manufacturing infrastructures.