CTC GmbH & KTM E-Technologies Unveil Cutting-Edge Joining Solutions for Urban Air Mobility

To help with future high-volume production of lightweight UAM vehicles, the Conexus coupling layer, developed by KTM E-Technologies, enables fast assembly of thermoset composites using the robotic ultrasonic welding process developed at CTC. Photo credit: CTC and KTM E-Technologies

When welding thermoset materials, the Conexus coupling layer, developed by KTM E-Technologies, is used as an enabler. This thermoplastic material is adapted to the specific thermoset matrix being used and can be applied directly to the component surface with reliability during the part manufacturing process, for example, in a press. During subsequent assembly, not only can fiber-reinforced components be joined together but injection-molded brackets or stiffening elements can also be integrated via welding or overmolding directly onto the part.

Together with CTC, cross-industry opportunities and new mobility solutions are being created,” says Stefan von Czarnecki, director sales and business development for KTM E-Technologies. “This comprehensive cooperation opens up new possibilities for smart and efficient lightweight construction.”

“New mobility concepts offer enormous potential,” says Marc Fette, CEO for CTC. “However, they also present significant challenges with regard to weight, cost, rate capability, quality level and ability to be certified. Robotic ultrasonic welding is one promising solution for both thermoplastic and thermoset composite materials to meet these challenges. We look forward to continued knowledge transfer and cross-industry collaboration with KTM E-Technologies, that will, no doubt, produce many other enabling solutions.”

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