After four years of successful collaboration with ENSAM Aix-en-Provence, NEXTEAM Group, and Airbus Helicopters, CT has completed the RECOMPOSE project. The project aimed to design and manufacture a rear drive shaft, located in the tail boom of the helicopter, made of carbon fiber, thereby improving helicopter efficiency, reliability, and overall durability, while also reducing weight and environmental impact. CT teams worked on all phases of the project, from designing the support components to preparing the manufacturing processes, adhering to the standards required for future aerospace certification.
The CT team in Marseille led the design of the shaft’s support components and successfully completed the Critical Design Review (CDR) with Airbus Helicopters. At the same time, risk analyses and production line and tooling architecture studies were conducted for all tools needed for the industrialization of the shaft, ensuring a reliable, reproducible process ready for series production.
From Toulouse, CT contributed to the development of a Structural Health Monitoring (SHM) system capable of detecting and locating potential damage on composite shafts before it affects helicopter operation. The system combines specialized sensors and advanced algorithms, including a neural network designed to identify defects even when helicopter vibrations generate signals that are difficult to interpret, paving the way for in-service defect detection.
Numerical and experimental tests were also conducted to verify its performance. In collaboration with the Vibrations and Acoustics Laboratory (LVA), monitoring of the bearings—another key component of the shaft—was developed.
A project promoting efficiency and durability
The RECOMPOSE project represents a tangible advance in the development of lighter, more reliable helicopters, contributing to a reduced environmental impact.
“What is most exciting about RECOMPOSE is that we finally have a drive shaft ready for production and certification. During the project, we learned a great deal about improving design and manufacturing processes, and we always ensured that every decision regarding materials and techniques contributes to reducing environmental impact without compromising helicopter safety or reliability,” says Simon Melot, Competence Developer Expert and RECOMPOSE Project Manager at CT Engineering France.
RECOMPOSE is yet another example of CT’s work, applying technical know-how and expertise to create effective, safe, and sustainable solutions, reflecting the company’s commitment to innovation and quality in every development.
This project is part of the RECOMPOSE (aRbrE COMPOSitE) project funded by the European Union NextGeneration EU, the DGAC (French Civil Aviation Authority), and supported by CORAC (Civil Aviation Research Council).
