GKN Aerospace Launches £12M ASPIRE Programme to Pioneer Next-Gen Composite Wing Technologies

A major global Tier One supplier to the aerospace, defence, and space industries has launched ASPIRE, a groundbreaking £12 million UK-based research and development programme aimed at advancing next-generation composite wing and flap structures. The three-year initiative, which officially commenced last month, will run through April 2028 and is designed to position the UK at the forefront of sustainable, high-performance aerospace manufacturing.

At the heart of ASPIRE is the development and testing of three full-scale composite wingtip variants, each reflecting a distinct structural philosophy and technology set. These wingtips will be subjected to ultimate load structural testing, providing a unique opportunity to validate advanced materials and manufacturing methods under highly relevant conditions.

• Variant One adopts a bonded assembly with multiple parts, aligned with GKN Aerospace’s established design philosophy.
• Variant Two features a quasi-isotropic co-infused resin transfer moulding (RTM) structure, incorporating state-of-the-art techniques such as automated fibre deposition, digital twin integration, and Pentaxia’s energy-efficient JouleTool.
• Variant Three explores more disruptive technologies, including non-standard fibre angles, low-energy dry fibre forming, and SmaRTM processing, aimed at pushing the boundaries of structural efficiency.

Key technological innovations being trialled include iCOMAT’s Rapid Tow Sheared (RTS) method for producing lightweight structures, and Carbon ThreeSixty’s stitched deltoid noodles—an eco-friendly solution using recycled carbon fibres aligned through Lineat’s AFFT process. These efforts are supported by advanced simulation tools developed by the University of Bath, enhancing analytical accuracy and predictive modelling.

In addition to the wingtip demonstrators, the ASPIRE programme will also deliver an optimised composite flap. This component will feature RTS skins, tailored fibre-placed brackets, and press-cured ribs using low-energy, out-of-autoclave moulding methods. Achieving Technology Readiness Level 6 (TRL6) for press-curing ribs is a key milestone, building on GKN Aerospace’s prior experience with the A350 flap production in Munich and supporting future single-aisle aircraft improvements.

John Pritchard, President of Civil Airframe at GKN Aerospace, emphasized the significance of the programme: “ASPIRE is a perfect example of the power of UK collaboration to drive aerospace innovation. It brings together SMEs, academic partners, and industrial leadership to accelerate the development of sustainable, high-rate composite wing technologies.”

The ASPIRE programme not only strengthens GKN Aerospace’s leadership in advanced aerospace manufacturing but also represents a pivotal step in creating a more efficient and environmentally sustainable aviation industry.