CT, a leading engineering company in technological innovation throughout the entire product lifecycle, leads the SAAT project—an initiative that marks a decisive step toward the future of aeronautical manufacturing. Its main objective is to advance the large-scale implementation of high-performance thermoplastic welding using ultrasound, a key technology for achieving more competitive, efficient, and sustainable production.

With SAAT, the aim is to develop solutions that enable high-quality welds in aeronautical structures, ensuring robust and flexible processes that can adapt to the industry’s demanding requirements.

SAAT Project objectives

The project pursues a series of strategic goals focused on technological excellence:

• Develop advanced thermo-mechanical simulation models to optimize the ultrasonic welding process.
• Design strategies for welded thermoplastic joints based on the Model-Based System Engineering (MBSE) methodology.
• Create an optimized and monitored welding head that integrates sensors and a control system.
• Develop a non-destructive inspection system based on vibrothermography, capable of assessing the quality of each joint in situ.

A strategic consortium to drive aeronautical innovation

The SAAT consortium covers the entire value chain, from technological development to final user validation. It is made up of four key companies that bring together knowledge, innovation, and industrial expertise. CT acts as the consortium leader, contributing its experience in advanced engineering and project management. SOFITEC participates as an aerostructure manufacturer, while MECASONIC contributes its specialization in ultrasonic welding equipment. SYSPRO provides expertise in automation and digitalization solutions. In addition, AIMEN participates as a subcontracted entity, serving as a leading technological center in composite processing, digitalization, and automation.

CT leads the digitalization and advanced simulation of the welding process

Within the project, CT leads the development of digital tools and advanced simulations, applying the MBSE methodology to define thermoplastic joints in structural components and optimize ultrasonic welding processes. This work accelerates innovation and ensures the reliability of every implemented solution.

The project’s results—including new engineering and simulation methods, a flexible welding head, decision-support tools, and an advanced inspection system—will be validated through a final demonstrator. These technical capabilities represent a fundamental step forward for the design and manufacturing of next-generation aircraft with zero emissions and high production rates.

A step toward sustainable aviation

With SAAT, CT reinforces its commitment to innovation and sustainability by driving technologies that are transforming the aeronautical industry. Thanks to its expertise in digital engineering, advanced simulation, and MBSE methodologies, CT Engineering continues to lead the development of solutions that bring the future of sustainable aviation closer.

Project Title (ES): Proceso de soldadura avanzada para la fabricación de aeroestructuras de composite termoplástico.
Project Title (EN): Advanced welding process for manufacturing thermoplastic composite aerostructures
Acronym: SAAT
Project: EXP – 00171201 / MIG-20241007
Duration: 09/03/2024 to 12/31/2025