Cevotec showcases FPP for complex aerostructures

Cevotec GmbH (Munich, Germany) presents new fiber patch placement (FPP) capabilities designed to help aerospace suppliers automate composite aerostructures that have remained manual despite years of automation efforts.

Positioned as the bridge between automated fiber placement (AFP) and hand layup, FPP enables robotic lamination for complex 3D geometries, variable-thickness regions and mixed-material assemblies — applications that typically fall outside AFP’s process window and become production bottlenecks at scale. 

At JEC World 2026, Cevotec introduces an aerospace demonstrator highlighting advanced layup features representative of secondary aerostructures produced in series environments. This demonstrator showcases high-precision robotic placement on complex geometries, with fiber and patch architectures not achievable using continuous-tow AFP systems.

Beyond this demonstrator, Cevotec draws on a portfolio of existing, application-driven aerospace demonstrators that underline the maturity of FPP for complex aerostructures. These include:

• An HTP fairing demonstrator, developed together with GKN and other partners under a grant-supported project, addressing complex geometry, local reinforcements and multi-material interfaces.
• A radome-inspired demonstrator, illustrating controlled fiber architectures and robust material handling for demanding functional and structural requirements.

These reference applications represent a broad range of high-value Tier 1 use cases, including radomes, nacelle structures, fairings, spar and rib reinforcements, and localized reinforcements in hybrid assemblies.

By enabling automation where it previously failed, Cevotec says that FPP supports suppliers in addressing key industrialization pressures:

• Scaling to higher production rates for current and upcoming single-aisle programs.
• Achieving cost and margin targets despite increasing volumes.
• Improving first-pass quality and reducing scrap and rework.
• Reducing reliance on manual, ergonomically challenging layup operations.
• Strengthening their technological readiness for next-generation aircraft platforms.

Cevotec’s FPP technology is implemented on its Samba Series systems, combining high-rate robotic motion with precise placement of load-oriented fiber patches, in a variety of sizes. The systems support:

• Load-path aligned fiber architectures with adjustable gaps/overlaps.
• High-precision, direct 3D layup within tight tolerance on intricate surfaces.
• Processing of difficult-to-handle materials, including dry fibers, prepregs, film adhesives and hybrid stacks.
• Vision- and sensor-based real-time process monitoring for placement accuracy and quality assurance.

This enables robust, repeatable automation for applications where previous automated layup approaches proved impractical. Based on a modular design approach, Samba Series systems can be configured and customized to match the application.

In addition to standard configurations for applications in aerospace and composite tank reinforcements, Cevotec introduces another innovation: A retrofit kit for existing robots, enabling access to FPP layup capabilities for user like R&D institutes and universities with compatible robots and small budgets.

Cevotec offers free-of-charge FPP manufacturing feasibility checks during JEC World, enabling aerospace suppliers to quickly assess automation potential for specific parts. Detailed ROI evaluations can follow for shortlisted applications, supported by Cevotec’s engineering and industrialization experts.

In addition to aerostructures, the company also highlights localized reinforcement solutions for composite tanks and pressure vessels, applying FPP to strengthen load-critical areas.

Tier 1 suppliers and OEM representatives interested in discussing specific applications are invited to book a meeting.

Visit Cevotec at Booth M99 in Hall 5.