Composites in the Aircraft Construction Industry

The use of composites is becoming increasingly more commonplace among aircraft manufacturers. Boeing used to use only a small amount of composites in their planes. However, today, composites can make 50 percent of the aircraft. What are some of the advantages and disadvantages of using composites?

New options in design

What makes composites so special? It is the way that this material is made. Composites are made from carbon fibre and plastics. This makes them just as strong as metal, yet not as heavy. That means a composite aircraft is just as strong as a plane made from metal, but much lighter.

Designers and engineers have new possibilities. Their goal is to maximize efficiency in fuel consumption, aerodynamics, and cutting down engine noise. One such example is the design of the sweeping wing tips that improves fuel consumption.

Parts of planes can be constructed in modules rather in one large piece. The parts can be shaped and sized to fit the need, improving the plane's structural integrity and cutting down on the cost in making it.

Composites are good for the budget and for the environment

These improvements have major benefits for the companies as well as for the environment.

For aircraft manufacturers, the more efficient their planes, the more money they save. Fuel cost is a major expense. Lighter planes use less fuel when they fly. The more aerodynamic design of the body also adds to this. When fuel cost can be reduced, this results in significant savings to the airline industry.

Other financial advantages include reduced costs in shipping parts. Smaller parts can be shipped at a cheaper rate. They also cost less to make. Using special tooling techniques enable parts to fit better at less expense. This brings financial benefits to both the aircraft maker and the airlines.

These improvement not only benefit companies in the industry, but they also benefit the environment.

Air pollution is greatly caused by the burning of fuel by airplanes during flight. Lighter airplanes burn less fuel, thus reducing the carbon emission into the air. That has less impact on the environment.

Not only that, but composites in aircrafts have enabled the possibility of construction an aircraft powered by the sun. For instance, the Solar Impulse aircraft will make its 25-day demonstration flight in the year 2015. This solar powered airplane was made from advanced composite materials and techniques that are environmentally friendly. This opens up new possibilities in reducing cost and impact of airplane operation in the future.

Challenges faced by composite aircrafts

The move toward composite airplanes do pose new challenges.

Because this material is new, special tools are required in production. Airplanes need a perfect surface to achieve maximum efficiency. Precision also ensures that the rigorous safety standards are met. Therefore, designers of composite tooling technology and aircraft manufacturers must collaborate in order to achieve the most benefits that composites can provide.

Airlines also face new challenges with composite planes. Repair technicians need to learn how to work with this new material. Boeing has made great strides in showing that their composite planes can be fixed with success. Small damages can be fixed by using a heat and epoxy to form new layers on top of the damage. Components are constructed to mount on other areas that may have a high risk of damage. Damage that is bigger in scale will need special repair, and technicians specially trained in this material will be needed. Constructing larger parts may make the plane stronger, but it makes repairs more difficult.

There is no question that composites will continue to play a big role in the construction of aircrafts. It is important to keep in mind, however, that with these benefits, there are also challenges that must be addressed.

Editor's Note: Amy Rice writes about composite materials for aircraft manufacturers, when not writing she enjoys playing adventure golf.

Some information about composite materials.

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