Airbus Explores Thermoplastics to Reduce Aircraft Weight by 10%

Aerospace companies consistently lead the way in material science, driving innovations to make aircraft lighter, enhance user experience, and improve environmental sustainability.

Airbus is now exploring the development of a new material for aircraft fuselages, aiming for a breakthrough that could reduce aircraft weight by up to 10%. This new material is also expected to lower cabin noise, thanks to its unique properties.

The material Airbus is focusing on is thermoplastic. That’s right—research is underway to develop this material in a unique way, similar to carbon fiber. It promises a lighter build without compromising on strength.

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Thermoplastic polymers offer a weight advantage over traditional carbon composites, which are currently used in major aircraft components. They are easier to recycle, repurpose, and produce with less energy, making them an environmentally friendly option.

To explore the potential of thermoplastics, Airbus has joined the Multi-Functional Fuselage Demonstrator (MFFD) consortium. This initiative is part of the EU’s Clean Sky 2 public/private funding program, aimed at advancing sustainable aerospace technologies.

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In production, thermoplastic composites allow fuselage sections to be assembled using innovative methods, reducing costs and time. A secondary goal of the MFFD is to facilitate thermoplastic composite fuselage barrel production, targeting a rate of 60 to 100 aircraft per month.

Traditionally, aircraft fuselages are assembled using rivets, but a new approach uses laser welding to join the sheets, which streamlines the process. This method not only makes the fuselage cleaner but also boosts production rates compared to traditional techniques.

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The innovations also enhance the material’s properties, reducing corrosion and minimizing vibrations. However, one of the challenges is that if the material gets damaged, specialized techniques are needed for repairs. Despite this, the high strength-to-weight ratio of the material ensures the aircraft remains lighter and more efficient.

The fuselage is more than just a shell; it houses vital electrical, mechanical, pneumatic, and hydraulic systems. Installing these systems after the fuselage is built adds to the weight, cost, and production time. A lighter and easier-to-assemble fuselage can help address these issues.

Thermoplastics offer a promising solution by eliminating or significantly reducing the need for heavy fasteners that are typically used in conventional metallic fuselage sections. This not only cuts down on weight but also simplifies production, paving the way for a more efficient manufacturing process.

Known as carbon fiber-reinforced thermoplastic polymer composites (CFRTP), these materials are moldable at high temperatures and solidify upon cooling. When intelligently integrated with cabin and cargo technologies, CFRTP composites could lead to over 10% weight savings per aircraft.

Additionally, CFRTP composites are easier to reuse and recycle compared to metallic or carbon fiber components, providing a significant advantage in sustainable aircraft production.