Published 4/9/2025

Daher celebrates Shap’in anniversary, highlights R&D developments

Two years after its launch, Daher’s technology center has been actively pursuing its ambitions to mature aerocomposites, from thermoplastics welding to rethinking their entire life cycle.

Edited by: Grace Nehls

Senior Managing Editor, CompositesWorld and Products Finishing

To achieve this ambition, Shap’in has spent two years developing solutions in automation, connectivity and flow optimization. In direct connection with Daher’s factories in the region, these processes are being tested and optimized for gradual deployment, initiating a ramp-up that will continue in the coming years.

This transformation dynamic relies on support by funding sources like the Council for Civil Aeronautical Research (CORAC), the French government and the region in which Shap’in is located. It also depends on open collaboration with startups, SMEs, aircraft manufacturers, academia and the IRT Jules Verne to explore new processes, test cutting-edge materials and optimize composites manufacturing. These partnerships are said to enable a faster transition from research to industrialization, relying on a network of expertise and advanced technological resources.

Among these advancements, Daher points to a technological breakthrough in fastener-free assembly at Shap’in, in which aerostructure weight could be reduced by up to 15%. Following its acquisition of Dutch company KVE in 2019, Daher has developed a patented induction thermoplastic welding technology. In November 2024, this innovation was validated at Shap’in with a fixed horizontal tail plane demonstrator for aircraft, confirming its industrial feasibility.

“Shap’in is the culmination of our ambitions in composites innovation and industrialization,” emphasizes Dominique Bailly, the R&D director at Daher and the head of Shap’in. “The validation of thermoplastic welding is a real example of our ability to transform a technological breakthrough into an industrial solution.”

Beyond advancements in assembly, Shap’in also is rethinking the entire life cycle of composite materials. In partnership with Daher’s Saint-Aignan factory, the tech center has implemented a structured recycling process in three stages:

Sorting and the collection of waste
Grinding and transformation into pellets
Reuse for the production of new parts.

This process has been applied to replacing the pilot’s rudder pedals of Daher’s TBM aircraft — which were historically made of aluminum — with pedals made from recycled composite materials. Approved by European authorities, they will be integrated into production starting in 2025.

To meet critical applications, Shap’in also has enhanced its expertise in composites machining. Thanks to a heavy-thickness machining machine funded by the French government under the France Relance program, Daher can now machine composite parts up to more than 2 centimeters thick. By mastering these processes, Daher has joined the select group of industrial players capable of addressing these markets.

“The more eco-responsible aviation of tomorrow will rely on these innovative processes and materials, and we have been preparing to meet this shift for more than 10 years,” adds Julie de Cevins, the chief sustainability officer at Daher. “Respect for the environment is at the heart of our technological roadmap. Early on, Daher identified advanced composites as a true catalyst — a ‘game changer’ addressing the major challenges of performance, weight reduction and production rates for aircraft manufacturers. With Shap’in, we are accelerating the efforts to decarbonize our products throughout their life cycle, from eco-design to the circular economy, with optimal management of the recycling of our production waste. We are convinced this approach represents a decisive asset for the entire industry.”