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Technologies for the Aircraft of Tomorrow
A350 XWB:FACC is a European Supplier Partner
SSJ100:Certi cation of Aircraft Structures by FACC
FP7:FACC Participating in European Cutting-edge Research
2712.10
2 takeoff F A C C C U S T O M E R M A G A Z I N E
EDITORIAL
Welcome,
dear Readers,
Civil aviation has been shaken by a massive crisis in re-
cent years, so there has been little cause for jubilation.
With the noticeable turnaround over the past months,
the industry has had an occasion or two to celebrate.
At the end of August, our customer Airbus announced
the ofcial start of production for the A350 XWB. The
latest promising development program of the Europe-
an aircraft manufacturer is happy news for FACC, too.
FACC has been contracted so far to do seven work
packages for components on the wings and engines
and the passenger cabins. These contracts guarantee
full order books and do much to ensure a sustainable
future for FACC business sites in Austria. The Airbus
A350 XWB is at least a tiny bit Austrian. You can read
on the following pages just what role FACC played in
making it so.
From Europe to far eastern Russia: There FACC
has a new market and with Sukhoi a new customer.
Its new regional aircraft, the Sukhoi Superjet 100, is
the rst passenger plane completely developed jointly
with Western aviation companies since the end of the
Soviet era. The Russian aircraft manufacturers objec-
tive with the SSJ100 is to cover the short and medium-
haul segment domestically while also serving Western
markets. Sukhoi picked FACC as a partner for modi-
cation, EASA certication and production of various
aerostructures. We report here on the details of this
large project.
You can read about these activities and other inter-
esting subjects in the new issue of take off. For all of us
on the Editorial Team, we wish you an enjoyable time
reading this issue
Andrea Schachinger
Editor
CORRECTION
The FACC take off 26 magazine originally issued on July 19th 2010
contained an article about the MS-21 aircraft that erroneously in-
cluded Intellectual Property information. All the information about
the MS-21 in this article shall not be considered as public and it is
not allowed to be used for any purpose without proper permission
through FACC AG. The concerned article has now been removed
from the magazine.
PS.: We welcome your ideas and comments
Published by: FACC AG, Fischerstrae 9, A-4910 Ried/Austria. Editorial Staff: Walter
Stephan, Thomas Pleli, Robert Machtlinger, Andrea Schachinger. Photos: Manfred Lang Kla-
genfurt, Airbus Toulouse, Alois Furtner Ried, SCAC Moskau, Eurocopter Donauwrth, APB
Seattle, Mark Thompson/Getty Images, Pointecker Mehrnbach, FACC Ried. Design and
Composition: Oskar Pointecker, 4941 Mehrnbach.
Cover: Translating Sleeve for the Airbus A350 XWB
04 A350 XWB: First delivery of translating sleeves
05 Inolvement of FACC in the A350 XWB programme expanded
07 FACC is a European Supplier Partner of Airbus
08 SSJ100: Certication of Aircraft Structures by FACC
10 FP7: FACC participating in European cutting-edge research
12 Milestone: 3,000th Shipset of Blended Winglets delivered
14 FACC honored by Embraer as a 2010 Supplier of the Year
15 High Flying Red Bull Racing is world champion!
CONTENTS
3takeoffF A C C C U S T O M E R M A G A Z I N E
The environment for the aviation in-
dustry has changed dramatically in
recent months. Or has it ?
In the near future, our customers
will speed up the completion rates of
the established aircraft families such
as the Boeing 737 and 777 and the
A320 and A330. This is promising
news in itself. On the other hand, the
delays in new aircraft programs con-
tinue to be a source of uncertainty,
which has compelled me to adopt the
somewhat dissonant note in the title
of this article.
You can add as a backdrop, the
uncertainty about global economic
conditions. European examples in-
clude the immediate nancial crisis
in Ireland along with Portugal and
Spain who are facing similar circum-
stances. Beyond Europe we see the
disconcerting monetary and scal
policy of the United States and the
seemingly uncontrolled growth of the
BRIC countries in general and China
in particular. The US dollar exchange
rate has responded accordingly tak-
ing a roller coaster ride up and down.
The dollar is and will remain the rel-
evant currency for aviation and to be
sure for FACC AG.
Our business environment is for-
ever highly dynamic. If we want to
play an active part in shaping this
environment positively, we as a com-
pany must take appropriate steps to
respond to this dynamism. Heres
how FACC can do it:
Research and development:
FACC invests a great deal in research
and development. This fact is evident
from the number of employees en-
gaged in research, by the technology
and production resources provided
for this purpose and from our nan-
cial outlays. The amounts involved
are impressive. We will nearly double
our research spending from EUR 30
million last year to over EUR 55 million
this year. These stepped up innova-
tion efforts are also yielding impres-
sive results already. They range from
revolutionary accomplishments in
material research - often achieved in
cooperation with the best in the world
- to advanced tooling techniques as
well as the development of new types
of front runner technologies and ef-
cient processes. One current project,
which is putting FACC in a position to
compete in large aerostructures, is
the development of a composite wing
box for a new medium-haul aircraft.
We will celebrate the ofcial roll-out
of the prototype in a few weeks with
the sponsoring customer along with
our partners.
Development programs:
Within this current business year,
FACC has been intensively involved
in several ongoing development
programs. Among the highlights are
complete passenger cabins for vari-
ous civil aircraft and business jets,
the control surfaces for the Russian
SSJ100, as well as numerous inte-
rior and structural components for
the A350. In the future, these pro-
grams will lead to billions of Euros in
sales for FACC and its partners and
will help to ensure a constant, high-
level of capacity utilization. Through
its participation in these programs,
FACC seeks to provide customers
with competitive, integrated solutions
that translate into increased program
revenues and sustainable protability
up and down the value chain.
Production partnerships:
In October of this year FACC suc-
cessfully completed the qualication
process for a new production facility
for a company that has been an im-
portant partner for years. Strata in Al
Ain, a subsidiary of Mubadala Hold-
ing in the Emirate of Abu Dhabi, has
delivered the rst production com-
ponents to FACC, ap track fairings
for the A330. This initial delivery is a
major milestone in the collaboration.
FACC provided support to Strata
in the planning and construction as
well as the certication of the facil-
ity to ensure compliance with criteria
specied by a disparate group of air-
craft manufacturers. We can say with
condence, that we have in concert
with numerous industrial partners,
designed and built the most modern
composite factory on earth.
FACC will continue to expand this
business model of production part-
nerships such as established with
Mubadala. In this case we have cho-
sen not to take a stake in the Al Ain
facility. However, with our much im-
proved nancial situation we plan in
the future to set up production sites in
US dollar based economic areas and
operate them ourselves. Our objec-
tive is to lay appropriate groundwork
for responding ideally to the require-
ments of the global aviation market
and to assist our customers in car-
rying out their internationalization
strategies as well as satisfying their
industrial assist obligations in their
markets. FACCs goal is for our cus-
tomers to benet from the latest tech-
nologies in the market, provide them
premier manufacturing performance
and maintain the constant dedica-
tion to perfection for which FACC is
known.
With research, new ideas and
forward-looking partnership models,
we want to create well-thought-out
benets and added value for our cus-
tomers. We believe, that in so doing,
this will be the key to our companys
greatest success.
Walter A. Stephan
FACC AG Chairman and CEO
The FACC Model:We Can Outperform in Troubled Times with Research and New Ideas
4 takeoff F A C C C U S T O M E R M A G A Z I N E
While the Airbus A350 XWB wont
take to the skies for the rst time for
a couple of years, a number of sup-
pliers have been working busily on
the aircraft in various factories for
quite some time. FACC AG is one
of them. In March 2010, it began
manufacturing the rst translat-
ing sleeves after a twelve-month
development period. The direct
customer of FACC is Goodrich
Aerostructures, the US group re-
sponsible for supplying the engine
nacelle systems for the A350 XWB.
FACC has been commissioned
to develop and manufacture the
translating sleeve including the
moveable blocker doors. FACC and
Goodrich have collaborated suc-
cessfully for years. At the end of
August, they were able to celebrate
a major milestone in their collabo-
ration with the on-schedule deliv-
ery of the rst translating sleeves
for the long-haul jet from Airbus.
These initial components under-
went numerous tests on engine test
benches at the Rolls-Royce facility
as engine development units. The
Trent XWB from Rolls-Royce is the
Milestone:First delivery of translating sleeves for the A350 XWB
Production of the Airbus A350 XWB was ofcially started in Stade in late August. Concurrently with this signicant programme milestone, FACC delivered the rst translating sleeves for the new long-haul aircraft from Airbus. More good news: FACC landed additional contracts and expanded its involvement in the A350 XWB programme.
FACC hands over the rst translating sleeve for the A350
XWB (: Jake Yu, Chief Engineer Acoustics, Goodrich;
Florent Mercant, Acoustic Engineer, Airbus; Eugene Chi-
en, Acoustic Engineer, Goodrich; Giorgio Mauri, Project
Manager, Goodrich; Michel Berud, Head of Supply Chain
Quality Development, Airbus; Franz Jungmeir, Program
Engineer, FACC; Tom Smith, Progam Associate A350
XWB, Goodrich; Christoph Zaunbauer, Director - Nacelle
Programs, FACC; Lukas Kinneswenger, Program Engineer,
FACC; Jay Wall, On Site Representant, Goodrich; Cornelia
Marsch, Program Engineer, FACC; Markus Hacksteiner,
Senior Manager Production, FACC).
5takeoffF A C C C U S T O M E R M A G A Z I N E
engine Airbus is offering to power
its new aircraft. The test results will
be applied to the further develop-
ment of the engine. The plan is to
deliver the rst thrust reverser units
suitable for series production to
Goodrich in mid 2011.
We have been working suc-
cessfully for years with our cus-
tomer Goodrich Aerostructures.
Together we have come up with
innovative technologies and prod-
ucts to make modern aircraft more
efcient, economical and environ-
mentally compatible, said Walter
Stephan, FACC CEO, at the initial
delivery. The delivery of the rst
translating sleeves is yet another
highpoint and underscores how ef-
fectively our two companies work
together.
FACC produces the translating
sleeves at its Facility 4 in Reichers-
berg, which went into operation in
2007. These components are four
meters in diameter and three me-
ters long. The facility is one of the
most modern production sites for
lightweight composite components
in the world and is aligned for the
greatest possible efciency and
productivity. A high degree of auto-
mation by the employment of new
processes in the surface treatment
before the bonding and innovative
manufacturing technologies for
high-performance acoustic panels
ensure cost-efcient production in
Austria as the place of production.
FACC expands involvement in A350 XWB programme
Airbus is increasing its use of
lightweight composite materials
in the construction of aircraft. The
fuselage of the A350 XWB is made
using carbon-ber reinforced plas-
tic, and overall, around 53 percent
of the airframe is made of innova-
tive, long-lived composite materi-
als. This approach makes the air-
craft lighter in weight, thus reducing
fuel consumption and maintenance
efforts. As a composite specialist,
FACC benets from the growing
use of ber-reinforced composite
materials in the latest aircraft pro-
gramme and is undertaking various
work packages:
Winglets
Besides being contracted to de-
velop and produce the spoilers for
the A350 XWB in 2009, FACC also
signed a long-term contract in 2010
with Airbus as Design-and-Build
supplier for the A350 winglet pack-
age. This contract has special sig-
nicance for FACC as it allows the
company to expand its expertise in
wing parts. It also enables FACC to
apply its years of experience in the
design, development and manufac-
ture of wing tips to the new model
of the Airbus eet.
In various winglet programmes,
including the ight test winglet pro-
totype for the Airbus A320, we have
been able to prove our innovation,
extensive manufacturing expertise
and global competitiveness, said
Robert Machtlinger, Vice President
Structures of FACC. We are all the
more pleased that Airbus has again
selected FACC as a prime contrac-
tor and systems supplier for its cut-
ting-edge long-haul aircraft. Based
on our advanced composite tech-
nology we will make every effort to
provide an important contribution
to the efciency and aerodynamics
of the A350 XWB.
In the modern winglet
production line of
FACC the rst winglets
for the A350 XWB will
be built in 2011.
This commitment underpins
FACCs favorable position among
the worlds winglet suppliers. The
responsibility for the development
and production of various winglet
systems has allowed FACC to de-
velop into a strong-performance
competency center for winglets.
The production line was planned
to fulll the requirements of high
automation and shorter produc-
tion time, as well as the use of the
smallest production area. As an
experienced winglet system part-
ner FACC can contribute many
6 takeoff F A C C C U S T O M E R M A G A Z I N E
In the A350 XWB programme, Air-
bus collaborates with aviation com-
panies around the globe, thereby
making its Extended Enterprise
approach a reality. About 6,000
highly qualied engineers are work-
ing worldwide at the suppliers and
partners of this programme plus an
equal number at Airbus itself. Joint
processes, methods and tools en-
sure a more efcient exchange
of information plus an integrated
3-D digital-mockup (DMU) and
a standard planning programme.
This allows Airbus and its suppliers
to work in parallel and in real-time
with each other.
Another way Airbus has height-
ened efciency is to have a smaller
number of primary suppliers and
award them larger work packages.
FACC has the status of European
Supplier Partner of Airbus and is
one of these select primary con-
tractors. The three Austrian facto-
ries are producing components and
systems for the wing and engines
as well as for various interior prod-
ucts for the A350 XWB. The involve-
ment of FACC in this programme is
important for ensuring a sustain-
able future for FACC business sites
in Austria. Over the years, FACC
has built up tremendous expertise
in nacelles, aerostructures and
interiors in a number of different
projects. These new contracts give
the company a chance to apply and
further develop its expertise.
innovations to the winglet design
and can obtain increased efcien-
cy, cost saving and weight reduc-
tion. Through ongoing product im-
provement, an efcient production
is assured.
Airbus and FACC will closely
cooperate in the development of
the winglets for the new A350 XWB.
The future serial production of the
FACC signs a contract
with Eurocopter on
the development
and manufacture of
door linings for the
A350 XWB.
The A350 XWB is also Austrian
winglets will be carried out in the
FACC manufacturing plant in Ried,
Austria, where an average of 100
employees will be working on the
programme at full production ca-
pacity in 2016.
Winglets are wing extensions
that increase the aspect ratio of a
wing and thus the lift generated at
the wingtip. The better aerodynam-
ics result in improved operation
efciency, lower fuel consumption
and a longer range.
PAX Door Linings
The long-time FACC customer Eu-
rocopter awarded a contract to
FACC in July 2010 to develop and
manufacture passenger door lin-
ings. The project includes com-
ponent design, engineering and
qualication, development and
purchasing of production tools, and
denition of materials and process-
es. Eight door linings are needed
for each A350 XWB. The plan is to
deliver the rst series components
in the second quarter of 2011. Eu-
rocopter is the main contractor and
system partner of Airbus for the
manufacture of doors in the next
family of long-haul Airbus aircraft.
In this contract, Eurocopter
puts FACC fully in charge of devel-
oping and manufacturing the door
linings, adding a new dimension to
these companies relationship. In-
stead of just supplying helicopter
components, FACC will now also
manufacture components for pas-
senger aircraft as part of its col-
laboration with Eurocopter.
7takeoffF A C C C U S T O M E R M A G A Z I N E
With its A350 XWB (Xtra Wide Body), Airbus is introducing a completely new family of long-haul
wide-body aircraft. It offers three
versions with typical three-class
seating for 270 to 350 passengers.
FACC is a European Supplier Partner in the A350 XWB programme of Airbus
Project/Customer
Translating SleeveGoodrich Corporation, USA
SpoilerAirbus, Germany
WingletsAirbus
Trent XWB Engine CompositesRolls-Royce PLC, UK
OSC Housings, Bins, Spacers & End CapsDiehl Aircabin, Germany
Door LiningsEurocopter, Germany
Smoke Detection Cover/CavitySiemens SAS, France
Work undertaken by FACC
Manufacturing development, tool design and production, qualication
and manufacturing of translating sleeves and moveable blocker doors
serving as lining for the Trent XWB engine.
Development, engineering, tool design and manufacture, qualication,
manufacture and industrialization of the 14 spoilers and two aperon
hinge panels per aircraft.
Development, engineering, tool design and manufacture, qualication
and manufacture of aerodynamic winglets.
Development, engineering, tool design and manufacture, qualication,
manufacture and industrialization for the carbon-ber-reinforced engine
components, customer consulting regarding jet engine development.
Development, engineering, tool design and manufacture, qualication
and production of various parts of the luggage compartments.
Development, engineering, tool design and manufacture, qualication
and production of eight door linings per aircraft.
Development, engineering, tool design and manufacture, qualication
and manufacture of smoke detection panels.
Airbus A350 XWB: Long-haul airplane of the future
The A350-900 XWB base version is
67 meters long and has a wing span
of 64 meters. It has capacity for 314
passengers and a range of 15,000
kilometers.
With 573 orders already placed
by 35 customers from around the
world thus far, the A350 XWB Fam-
ily is already one of the fastest sell-
ing airliner programmes ever.
INFO
8 takeoff F A C C C U S T O M E R M A G A Z I N E
With its Sukhoi Superjet 100, the
Russian aviation industry has de-
signed a modern regional jet to
meet the needs for short and me-
dium-haul ights domestically and
also to be used in western markets.
Along with the type certication
from the Russian state aviation au-
thority Interstate Aviation Commit-
tee (IAC AR), the SSJ100 also has
to satisfy European standards of
ight as well as be approved by the
European Aviation Safety Agency
(EASA). In the course of develop-
ment, the aircraft manufacturer
Sukhoi entered into strategic part-
nerships with European aviation
companies to have them assist with
aircraft development and certica-
tion.
Focus on lightweight de-sign and stable production
One of these partners is FACC
AG. Sukhoi has contracted FACC
to modify, certify and produce the
movable parts made of composite
materials. The work package con-
tains the seven main components:
elevators, rudders, ailerons, spoil-
ers, air brakes, landing aps and
pylon fairing. The top program goal
is to obtain EASA approval of the in-
dividual components with their high
standard of engineering. The cus-
tomer can benet from the years
of experience FACC has in compo-
nent development, production and
certication and in the application
of European regulations. FACC is
making use of proven designs and
technologies in the modication of
the aircraft, allowing component
families already in production at
Sukhoi to be optimized in three re-
gards: reduced weight, simplied
production and a stable manufac-
turing process. In detail, FACC is
focusing its efforts on revising the
designs, calculating and analyzing
the individual components, den-
ing the processes, and dening
and procuring the production tools.
In collaboration with suppliers, new
materials and purchased parts are
developed and qualied in accord-
ance with FACC standards. Con-
formity with strict weight limits and
tough component requirements is
assured. FACC is also in charge of
producing and coordinating the en-
tire documentation comprising over
350 different documents such as
plans, specications, manuals, etc.
Pushed to the limits during testing
The rst parts that FACC will deliver
will be used as test components
and will undergo through tests to
determine whether they meet the
required criteria for approval. In
static tests, the components will
be subjected to their maximum al-
lowable load, the design ultimate
load. This value is 1.5 times the
design limit load which is applied
to the aircraft structure in normal
operation.
In addition, the components
undergo fatigue testing that simu-
lates a lifecycle of the aircraft to
test how the aircraft responds over
time and to reveal potential fatigue
risks. FACC will analyze the nd-
ings from the different tests with
great care and incorporate them
into the production of the series
Sukhoi is seeking approval in Europe from aviation authorities for its new SSJ100 regional jet. FACC is making available its broad expertise on aerostructures and has been selected by the Russian aircraft manufacturer as a partner for the modi-cation, certication and production of various composite components.
SSJ100:Certication of Aircraft Structures by FACC
Russian aircraft manufacturer Sukhoi has contracted FACC
as its partner to modify, certify and
manufacture the movable parts for the
SSJ100.
9takeoffF A C C C U S T O M E R M A G A Z I N E
parts. The plans call for FACC to
deliver all components of the entire
work package in December 2011
for rst article inspection. Once
they are approved, FACC will pro-
duce two shipsets of movable parts
per month.
Enlarged market and product range
With this contract, FACC is expand-
ing its product range for aerostruc-
tures because some parts of the
work package such as the land-
ing aps, rudders, ailerons - are
being manufactured by the aircraft
supplier for the rst time. In addi-
tion, this is being done in Russia,
a promising new market for FACC.
With the expertise FACC gains from
this contract, it has a chance in the
future to further rene its products
and services in the Structures seg-
ment. This is yet another step for
FACC in its aspiration to provide
complete system assemblies with
services ranging from initial design
all the way to efcient series pro-
duction. With its implementation of
this strategy, FACC can respond
even better to the needs of its cus-
tomers and provide complete solu-
tions of the best quality.
Super Features, Super Technologies, Super Economics: The Sukhoi Superjet 100
Sukhoi Civil Aircraft Company (SCAC) designs,
develops and builds the Superjet 100 family. This
family consists of aircraft with seating for 78 and 98
in the basic versions SSJ100/95B and SSJ100/75B
and in the longer-haul versions SSJ100/95LR and
SSJ100/75LR. The SSJ100 belongs to the new
generation of modern and environmentally friendly
regional jets. The SSJ100 has superb technical and
operational traits that make it highly competitive. It
is economical and easy to operate and maintain.
The SSJ100 is newly designed especially for the
100-seat segment and combines the economy of a
regional jet with the comfort of a jet developed for
long distances.
The rst SSJ100 left the SCAC nal assembly
plant in Komsomolsk-on-Amur, Russia, on Sep-
tember 26, 2007. Its maiden ight was in May 2008.
INFO
10 takeoff F A C C C U S T O M E R M A G A Z I N E
In January 2007, the European Un-
ion started the 7th framework pro-
gram for funding scienti c activity
in Europe (FP7 for short). Within
this framework programme, the
European Commission supports
development activities in the area
of transport with funding of EUR
4.1 billion. In the major eld of aero-
space, nancial support is reserved
for technology development to help
in the construction of aircraft that is
more fuel ef cient and less noisy.
The FACC Research Depart-
ment is currently participating in
two major development projects.
In the rst, called MAAXIMUS
(More affordable aircraft trough ex-
tended, integrated and mature nu-
merical sizing), FACC is developing
fuselage frames for a single-aisle
aircraft. The second, the CleanSky
project ORCA (optimized large
scale engine CFRP annulus ller)
involves developing a composite
solution for an annulus ller to the
series production stage.
Lighter, cheaper, faster
MAAXIMUS is a large-scale co-operation project with 57 partners
from 19 countries. Along with air-
craft manufacturers such as Airbus,
Dassault and Bombardier, many
rst-tier suppliers are participating
as well, such as Alenia, Latecoere
and also FACC.
The main goal of the project is
to develop a composite fuselage
that is 10% lighter, 10% more cost
effective and assembled in 50%
less time than the best known so-
lution. To achieve these ambitious
goals, the project is divided into
two platforms. In the rst platform,
the work focuses on the fully-virtual
development of an aircraft fuselage.
Well-known simulation software
suppliers as MSC and Abaqus are
used for developing software solu-
tions in cooperation with Airbus to
allow the nearly full development
of an aircraft on a computer. Unlike
the automotive industry, where this
approach is a well-known standard,
the aircraft industry is still forced to
verify single parts and units in com-
plicated tests.
Integrated means lighter
The second, the so-called physical
platform, is developing a full-size
demonstrator of a fuselage seg-
ment in order to verify the results
of the virtual platform in a series
of extensive tests. In the process,
highly innovative production meth-
ods, such as one-shot skins with
integrated stringers are to be tested
in a close-to- ying environment.
What FACC contributes to the
project are the circumferential stiff-
eners for the fuselage known as
the frames. Their main purpose is
to help stabilize the skin and fasten
the passenger oor.
Conventional frame designs
are produced in a differential proc-
ess, i.e. several sub-components
have to be assembled to a frame.
Besides the greater assembly ef-
fort, this approach requires un-
necessarily thick parts because
account has to be taken of overlap-
ping and drilled holes. In addition,
the parts currently used require a
The European Commission is funding high-end re-search for aircraft that is quieter and more fuel ef -cient. As a rst-tier supplier in the aircraft industry, FACC is involved in the development of new tech-nologies from the very outset.
FP7: FACC participating in European cutting-edge research
MAAXIMUS aims at achieving the fast develop-
ment and right- rst time validation of a highly-
optimised composite fuselage.
MAAXIMUS More Affordable Aircraft through eXtended, Integrated and Mature nUmerical Sizing
FACCs contribution:Development and manufacture of an integral
fuselage frame
Conventional design with cut-out stringer pass-
through (blue) and the integrated FACC solution
(yellow)
11takeoffF A C C C U S T O M E R M A G A Z I N E
high amount of post-processing
to ensure the pass-through of the
stringers.
The FACC Research and Devel-
opment Department has come up
with a process that allows the net-
shape parts to be manufactured in
one shot, with no need for an auto-
clave. Manufacturing is done with a
resin-infusion process, where the
dry, stabilized carbon- ber preform
is saturated with resin applied in a
vacuum. FACC did the design and
layup for the preform in coopera-
tion with EADS Innovation Works
Germany in Munich.
With all functions now integrat-
ed in a part, total weight was re-
duced by more than 10 percent and
part stiffness was improved. This
research project helps FACC to
increase its marketin uence even
more in the aerostructure segment.
Engines for the future
As part of the ORCA project FACC can also present a new develop-
ment in the eld of aircraft engines.
In cooperation with the University
of Applied Sciences in Rapperswil
(CH) and Rolls-Royce plc (UK),
FACC is developing an annulus ller
in composite technology. It is part
of a new engine developed in the
CleanSky project. Although based
on the currently largest engine, the
Trent 1000 (exclusively on Boeings
787 Dreamliner), the new engine
was optimized regarding fuel ef -
ciency.
High production rates are a must
An annulus ller is a part for what
is called the cold area of a bypass
engine and is mounted directly
Annulus ller assembly on an engine
Metal version and a possible CFRP design for an
annulus ller
between the fan blades. Its ma-
jor task is to direct the air stream
to the fan blades. The part rotates
at high speeds so it is loaded with
several tons of centrifugal forces.
Yet it needs to maintain its speci-
ed geometry under all ight con-
ditions to optimize engine perform-
ance. At the same time, the part
must be ductile enough to survive
a hailstorm. It must be cost ef cient
in mass production and not cause
damage to surrounding parts in
case of a part failure.
These contrary requirements
can be best ful lled with the use
of carbon ber reinforced plastic
(CFRP). The FACC Research and
Development Department is per-
forming component design analy-
sis in cooperation with the Uni-
versity of Rapperswil. FACC bears
sole responsibility for preparing the
part for mass production in which
costs are minimized and ef ciency
is high.
As one engine requires 18 llers,
FACC needs to deliver about 40
parts a day based on the current
production rate. Given the produc-
tion plans of major aircraft manu-
facturers, as many as 80 llers a
day need to be produced. These
quantities require a robust and fast
production process that delivers
consistently high part quality and
minimal scrap rates.
The nal ller, co-designed and
manufactured by FACC, will be as-
sembled in an aircraft as part of the
research project and tested in ight
at end of 2013 in order to verify
ight capability.
ORCA optimized large scale engine CFRP annulus ller
FACCs contribution:Development and manufacture of a CFRP
annulus ller
www.maaximus.eu
www.cleansky.eu
Contacts FACC AGR&D Department
Johannes Noisternig
+43 59 616 1436
MAAXIMUS
Le Huong Nguyen
+43 59 616 1775
ORCA
Konstantin Horejsi
+43 59 616 1842
INFO
12 takeoff F A C C C U S T O M E R M A G A Z I N E
The development and production of winglets has evolved a core competence of the FACC AG since the delivery of the rst shipset in 2002. A very spe-
cial milestone was celebrated just recently with the delivery of the 3,000th shipset of Blended
WingletsTM to the U.S. customer Aviation Partners Boeing. The celebrated shipset
left the Ried facility for Renton, Seattle where the aerodynamic, fuel-saving
wing tips were mounted onto an Air China Boeing 737-NG.
FACC hand over the 3,000th Shipset of
Blended Winglets for an Air China 737-NG
to Aviation Partners Boeing tr. Drew
Brennan (Supply Chain Manager, APB),
Robert Machtlinger (VP Structures, FACC),
Brian Harvey (Director of Contracts, APB),
Patrick Lamoria (Vice President Sales,
APB), Walter Stephan (CEO, FACC), Dean
Poor (Vice President Operations, APB),
Bernhard Matzner (CFO, FACC), Thomas
Pleli (CCO, FACC), Don Camillo (Direc-
tor of European Operations, APB), Martin
Bgl (Director Aerostructures Programs,
FACC), Sidney Anderson (Director Op-
erations, APB), Christian Strobl (Program
Manager, FACC), Mary Dunaway (Head of
Supply Chain Management and Contracts,
APB) und Tim Pohlenz (Quality Assurance
Manager, APB)
Milestone:3,000th Shipset of Blended Winglets delivered
During a recent visit of Aviation
Partners Boeing (APB) representa-
tives to FACC Ried in mid October,
the winglets were of cially handed
over by Walter Stephan, Chairman
and CEO of FACC. Innovative
companies such as APB always
present interesting challenges,
said Stephan. Thanks to our sys-
tem solutions expertise and our
profound technical know-how; we
could meet the stringent require-
ments of APB in terms of complex
assemblies and high production
rates. Supported by the excellent
partnership of our two companies
we could optimize the winglet tech-
nology and thus ensure an ef cient
series production. We are extreme-
ly proud to be recognized by APB
as a long term partner for the sup-
ply of Blended Winglets.
Aviation Partners Boeing lo-
cated in Seattle - is a joint venture
between Aviation Partners, the in-
ventor of the Blended WingletTM
technology and the airplane manu-
facturer Boeing. APB are responsi-
ble for marketing the aerodynamic
wing tips and Mr. John R. Reimers,
13takeoffF A C C C U S T O M E R M A G A Z I N E
President and CEO of APB, pro-
claimed: Congratulations to the
entire FACC team. The delivery of
the 3,000th Blended Winglet set is
a momentous achievement that
few in our industry get to experi-
ence. That you have reached this
milestone in just the eight year of
our program together, speaks to
both the capability of FACC and the
value of the product in the market
place.
APB and FACC:A partnership addicted to success
The cooperation between the
two aerospace suppliers began in
2002 when APB awarded a con-
tract for the original serial produc-
tion of 120 shipsets of Blended
WingletsTM. In April 2010, APB ex-
tended the contract for the entire
lifetime of the product and ap-
pointed FACC as the single source
supplier to APB and Boeing Seattle
of Blended WingletsTM for the air-
craft models Boeing 737-700/-800,
Boeing Business Jets, Boeing 757-
200 and Boeing 737-900ER. FACC
now manufactures all production
and retrot Blended WingletsTM.
The 3,000 shipsets were installed
on Boeing airplanes for 168 air-
lines, among them are Southwest
Airlines, Ryanair, American Air-
lines, Continental Airlines, Alaska
FACC employees and representatives from Aviation Partners Boeing celebrate the delivery
of the 3000th shipset of Blended Winglets.
Airlines, Copa Airlines, Delta Air-
lines, Air Tran, Gol Airlines, West-
Jet, Turkish Airlines, Xiamen Air-
lines, Air China etc. Deliveries of a
similar volume are planned for the
next ten years. As a subcontrac-
tor of Aviation Partners Inc., FACC
have also manufactured and de-
veloped the winglet prototypes for
the Airbus A320.
Dean Poor, Vice Presi-
dent Operations, and
Patrick Lamoria, Vice
President Sales, both
APB, rejoice together
with FACC CEO Walter
Stephan in the im-
portant programme
milestone.
14 takeoff F A C C C U S T O M E R M A G A Z I N E
The award was given Mid Novem-
ber during the Embraer Supplier
Conference in So Jos dos Cam-
pos/, Brazil.
We all at FACC are very proud
of having been chosen once again
as one of Embraers Suppliers of
the Year for 2010. We achieved this
prestigious award as a result of
our innovative technology and high
production quality that was accom-
plished through a major commit-
ment from everyone at the Interiors
division of FACC, commented
Walter Stephan, Chief Executive
Ofcer of FACC. The efforts under-
taken by FACC have signicantly
contributed to an on-time instal-
lation of the Phenom 300 interior
and a successful production ramp
up from 1 to 30 aircraft within one
year. Stephan took the occasion to
thank both Embraer for their con-
dence in FACC and the FACC team
for their hard work to accomplish
the Supplier of the Year award.
The Supplier of the Year is Em-
braers recognition of the progress
of its best suppliers, in terms of
improved quality and efciency of
the products and services as well
as exibility, delivery reliability, cus-
tomer support and innovation.
For the second consecutive year, the FACC AG was named as an Embraer Supplier of the Year. With this award the Brazilian aircraft manufacturer honors the excellent performance of FACC in quality, exibility, delivery reliability, customer support and develop-ment in the category Interior.
FACC Honored by Embraer as a
2010 Supplier of the Year
FACC and Embraer
FACC has been a supplier of Embraer since 2006.
Initial orders included various interior components
for the executive jets Phenom 100, Phenom 300 and
Lineage 1000. In 2008, Embraer awarded FACC the
contract for the development and manufacture of the
complete passenger cabin of the executive jet mod-
els Legacy 450 and Legacy 500.
15takeoffF A C C C U S T O M E R M A G A Z I N E
From 0 to 100 in just six years: the Red Bulls took the fast lane to success. The Red Bull Racing Team saw a long-standing dream come true in the 2010 racing season when it won two Formula 1 world championship titles. These victories are the latest crowning touches to the unique success story the Austrian beverage company has had in sports.
Two consecutive Sundays will be-
come holidays for Red Bull Rac-
ing. On the last Sunday of racing
for the Formula 1 in Abu Dhabi, the
Austrian racing team captured the
drivers title to make Sebastian Vet-
tel the youngest Formula 1 world
champion of all times. And that
was just one week after clinching
the constructors title. Energy drink
maker and team owner Dietrich
Mateschitz was understandably
elated. For the champion maker,
it is the biggest sports triumph his
corporation has ever had and a
conrmation of his intensive activi-
ties as a sports sponsor. The bever-
age producer sponsors about 500
athletes worldwide, including many
athletes involved in extreme and
unusual sports of many kinds, from
aerobatics, motorcycle acrobatics
and cliff diving to mountain climb-
ing and surng.
Six years have passed from the
Red Bull Racing Team entering the
premier arena in motor sports to
reaching the summit. In 2004 Red
Bull acquired the F1 racing team
Jaguar Racing. From the outset,
Red Bull Racing performed re-
spectably on the racetrack. It had
its rst podium win in Monaco in
2006. Since then the team has had
podium nishes every year. What
makes Red Bull so unique from
everything that preceded it is the
fresh wind it brings into promoting
its F1 program; for instance, the
daily paddock newspaper The Red
Bulletin, the Formula Una Girls in
the early years and the Energy Sta-
tion, which plays host to the entire
paddock with its open-door policy.
The 2010 racing season is the latest
milestone in the teams still short
Formula 1 history. With its strong
driving duo that combines Mark
Webbers experience with Sebas-
tian Vettels youthful talent, the
team captured nine victories in 19
races to clinch the big double in an
exciting nale: the world champion-
ship titles for drivers and construc-
tors.
High FlyingRed Bull Racing is world champion!
Portrait of Red Bull Racing
Owner: Dietrich Mateschitz
Team principal: Christian Horner
Chief technical ofcer: Adrian Newey
Drivers: Sebastian Vettel, Mark Webber
Grand Prix participation: 106
Victories: 14
Pole positions: 20
World championship titles: 2 (drivers and constructors 2010)
FACCA-4910 Ried/Austria, Fischerstrae 9
Tel. +43/59/616-0, Fax +43/59/616-81000
e-mail: [email protected], www.facc.at
Our excellent partners at FACC completed the 3,000th shipset of Blended Winglets in October, 2010. Under
the steady leadership of CEO Walter Stephan, their performance has inspired us to extend our collaboration
for the life of the 737-NG and 757 programs. Fly to aviationpartnersboeing.com. The future is on the wing.
3,000 SHIPSETS IS JUST THE TIP OF THE STORY.