Thermoplastic Composite Materials for High-Speed Aerospace Manufacturing

Boeing and Airbus are investigating advanced thermoplastic composite materials, which can be reshaped, reheated, and welded, thereby reducing curing times and enabling automated production for next-generation jets targeting approximately 100 units per month. These thermoplastic composites will be replaced by aluminium for future airplane models, as these composites are lightweight, which results in fuel savings and lower emissions.

Both OEMs are researching the next generation of narrow-body aircraft, which are the A320 and 737 series replacements. They are investigating robotic assembly, composites, and lighter materials, such as thermoplastics, to meet demand and increase output. In addition to materials, robotic assembly automation, welding/joining methods (rather than rivets/bolting), and out-of-autoclave/rapid consolidation processes are all of great interest. Using thermoplastics with welding (ultrasonic, induction, etc.) minimizes cure times and improves repair/joinability by allowing for reheating or shaping.

Lower half of a large thermoplastic fuselage built by GKN and Airbus (Source: Reuters)

What makes thermoplastics suitable for "high-speed" production?

They can be reheated and welded (reducing rivets and fasteners), shaped and consolidated quickly (minutes rather than hours), and do not require lengthy autoclave cures, all of which allow for significantly faster output rates and automation. Not only are OEMs and supply-chain R&D promoting thermoplastics for their speed and weight, but also for their recyclability, reduced environmental impact, and compatibility with decarbonization objectives.

Also read: High-Impact Performance Polymer Composite Structure Consisting of Construction Sand Particles