Fraunhofer IGCV demonstrates thin-walled, intricate helicopter inner door shells

Fraunhofer Institute for Casting, Composite and Processing Technology IGCV (Fraunhofer IGCV, Augsburg, Germany) is presenting how sheet molding veil (SMV) — a composite material designed to replace traditional sheet molding compound (SMC) — enables lightweight, cost-efficient solutions for geometrically challenging and structurally demanding structures and beyond.

In 2025, the team presented an SMV helicopter door shell, demonstrating how geometrically demanding composite structures can be manufactured efficiently, flexibly and at scale using discontinuous fibers for a specialized nonwoven material, with fiber volume contents greater than 40%. This helicopter door was developed within the research project LIGHT, funded by the Bayerisches Staatsministerium für Wirtschaft, Landesentwicklung und Energie within the BayLu program (read more about it here).

This year, the door is back — and on display at the JEC Innovation Planet (Booth D119, Hall 6). The Fraunhofer IGCV team is also available to talk composites, manufacturing innovation and what’s next for aerospace structures. 

Fraunhofer IGCV stands for application-oriented research with focus on efficient engineering, networked production and smart multi-material solutions. Fraunhofer IGCV aims (1) to combine R&D in the areas of lightweight casting technology, fiber composites and automated production, (2) to develop innovations for the industry and (3) to drive interdisciplinary research in automotive engineering, aircraft construction as well as mechanical and plant engineering.

Visit Fraunhofer IGCV at Booth L142 in Hall 5.