The FUDOS project, funded under the German research call with reference FKZ 20Y1709B, set out to design and validate a new architecture for a future door system for large transport aircraft. The primary technical objectives were to reduce the overall mass and integration cost of the door‑airframe interface, to enhance customer value through improved operational and maintenance characteristics, and to provide a robust, autonomous door‑handling concept with advanced state monitoring and misuse prevention. The project was carried out from 2016 to 2023, with a final report issued on 28 March 2023.
The technical work was organised into three main work packages. Work package 1 focused on the global architecture and integration of the door into the fuselage. A demonstrator was assembled in Hamburg, incorporating the full control and cabin‑side door panel, and then shipped to the Zentrum für angewandte Luftfahrt (ZAL) in Donauwörth for rigorous testing. The demonstrator’s delivery condition is shown in Figure 4 of the report, and it was subsequently displayed at the International Air Show (ILA) 2022, where it received positive feedback from industry observers.
Work package 2 addressed the optimisation and redevelopment of the door system. In the first phase, several candidate concepts were evaluated (AP 2.1–2.4). The most promising approach, the “Electrified Multi‑Latch” system, was selected in a joint workshop with Airbus Operations (AiO) in February 2020. This concept integrates an electrically actuated latch mechanism with a multi‑latch arrangement that allows for rapid, hand‑free operation while maintaining high safety margins. The design includes a cabin‑side door panel and an intuitive control concept for both interior and exterior use. Detailed mechanical sequencing and actuator trajectories were documented in a door‑sequence description, which guided the selection of actuators and control units from the supplier Wittenstein. Sensor integration, including single‑coil and double‑coil inductive sensors, was specified to provide precise position feedback and to detect any abnormal conditions.
Work package 3 concentrated on the development of door‑system components. The team produced a set of component designs that satisfy the stringent weight and reliability requirements of modern airframes. The demonstrator’s electrical actuators and control units were tested for performance, showing reliable operation under simulated flight conditions. The project also produced three European patents (EP 3995393 B1, EP 3915869 A1, EP 4129819 A1) covering key aspects of the latch mechanism, sensor integration, and control logic.
The collaboration involved Airbus Helicopters Deutschland GmbH, Airbus Operations, the ZAL, and the German research institute PTLF. Micro‑Epsilon, a partner with 30 years of experience in inductive and eddy‑current sensor technology, contributed critical expertise in sensor design and integration. The project’s governance structure included a project‑structure plan and a milestone schedule, with adjustments documented in Table 2 of the report. Regular meetings and workshops ensured alignment across the partners, and the final demonstrator was delivered to the ZAL for handover to Airbus Helicopters’ integration phase.
Overall, the FUDOS project achieved a demonstrator that validates a lighter, cost‑effective door architecture with advanced automation and safety features. The technical results, combined with the collaborative framework, strengthen Germany’s position in the development of next‑generation aircraft door systems and support the broader goals of the German aviation research programme to enhance efficiency and competitiveness in the global aerospace market.