Montana Aerospace’s Belgian subsidiary Asco Industries has presented Airbus with a full-scale prototype of a hybrid Rear Secondary Structure for the manufacturer’s next-generation single-aisle aircraft programme. Demonstrated in Toulouse, the rear fairing around the engine pylon combines composite, metallic and thermoplastic elements. The concept is intended to reduce structural weight, simplify final assembly and support lower-cost, high-rate production, but no series-production award has been announced.
The project began in 2022 under a Collaborative Research Agreement between Airbus Airframe Propulsion in Toulouse and Asco. It covers concept design, structural sizing and the manufacture of two full-scale prototype assemblies during 2026.
The structure uses carbon-fibre-reinforced plastic skins produced through resin-transfer moulding, together with aluminium and titanium interfaces, thermoplastic frames and injection-moulded thermoplastic components. Its integrated architecture is designed to enable pre-assembly, component interchangeability and easier maintenance.
Airbus will now continue evaluating the concept at complete-pylon level, including installation trials on a representative next-generation pylon structure. The work broadens Asco’s activities beyond its established wing-structure business, while the specific Airbus aircraft model, expected performance gains and any future production decision remain undisclosed.