Montana Aerospace has reached a development milestone in its collaboration with Airbus on a hybrid metallic-composite Rear Secondary Structure (RSS) fairing for a next-generation single-aisle aircraft programme. Its Belgian subsidiary, Asco Industries, presented a full-scale prototype assembly to Airbus stakeholders in Toulouse, demonstrating the maturity of the multi-material design.
The collaboration began in 2022 under a Collaborative Research Agreement between Asco and Airbus Airframe Propulsion in Toulouse. The programme covers concept development, structural sizing, and the manufacture of two full-scale prototype assemblies in 2026.
CFRP and Multi-Material Design
The RSS concept combines carbon fiber-reinforced plastic (CFRP) skins manufactured using resin transfer moulding (RTM) with aluminium and titanium structural interfaces. Thermoplastic frames and injection-moulded thermoplastic components complete the assembly, bringing together different materials and manufacturing processes within a single structure.
The design aims to balance structural weight, cost, and manufacturability while accommodating future high-rate production. According to Montana Aerospace, the targeted use of composites reduces structural weight compared with legacy solutions. An integrated, plug-and-play assembly concept is also intended to reduce final aircraft installation time, lower costs, simplify field maintenance, and enable component interchangeability.
Further Evaluation at Pylon Level
Following the prototype demonstrations, Airbus plans to evaluate the concept at complete pylon level, including installation trials using a representative next-generation aircraft pylon structure. The work could support further development of hybrid metal-composite structures for aircraft applications.
For Asco, the programme also extends its capabilities beyond its traditional focus on wing structures and complex structural components. The company is exploring opportunities in pylon parts and assemblies, alongside multi-material structures that combine its established metallic engineering expertise with composite and thermoplastic technologies.
The development forms part of Montana Aerospace’s broader effort to expand its aerostructures capabilities through research, materials engineering, and integrated manufacturing. The company operates across Europe, North America, and Asia, supplying components and assemblies for aerospace applications.
Source: Montana Aerospace | News
