Composites reinvent aerospace, AAM and space
Celebrating National Composites Week, CW shares ways in which composites continue to make a significant impact in aerospace and space market developments.
Source | Infinite Composites, EHang, Patz Materials and Technologies, Intuitive Machines, General Atomics Aeronautical Systems Inc., AIMEN (DOMMINIO project) and Collins Aerospace.
Over the years, composite materials have been major drivers in aerospace innovation and efficiencies. Recent trends have shown a significant increase in their use — particularly in commercial aircraft — where the material now accounts for more than 50% of the primary structure in some models, like the Boeing 787 and Airbus A350. The last few years have also seen a growing interest in thermoplastics due to their potential for faster production times and recyclability, driving further advancements in manufacturing processes such as AFP and out-of-autoclave (OOA) curing. Forecasts suggest that this sector will reach a value of $62 billion by 2030 with a compound annual growth rate (CAGR) of 10.8%.
Not to be forgotten, advanced air mobility (AAM) has made a rapid ascent in popularity, a market in which composites have become mandatory due to stringent performance and regulatory demands. Crucial to maximizing energy efficiency, and enabling the necessary range and payload capacity with battery-powered propulsion systems, the use of composite materials — particularly carbon fiber — is almost always a given whenever a new company emerges in this space. More aerodynamic shapes and integration of complex features, resistance to corrosion and fatigue and other factors make these materials so important to the commercial viability of AAM services.
In addition, New Space has become a burgeoning economy, with composite materials making applications like SpaceX’s Starship, Rocket Lab’s Electron rocket and OneWeb’s satellite structures a reality. Light weight, high strength, thermal stability, and structural integrity and resiliency all ultimately contribute to lower launch costs and improved orbital longevity, which are essential for advancing the New Space industry’s goals of cost-effective, frequent and sustainable access to space.
For National Composites Week, CW is providing daily roundups starring some of the prominent end markets in which composite materials greatly contribute. Each roundup comprises relevant published content to explore and read.
Note: Below covers only 2023-2024 articles for these topics. For other related content (including news and products), please visit CW’s markets page.
AAM
In the not too distant future, point-to-point, limited-distance, piloted and autonomous air travel for people and cargo will be the norm. Composites will make it possible.
As the advanced air mobility market begins to take shape, market leader Joby Aviation works to industrialize composites manufacturing for its first-generation, composites-intensive, all-electric air taxi.
BOLDair’s composite enclosure, compression structures and thermal runaway management enables high-performance electric energy storage.
This CW Tech Days features subject matter experts exploring the materials, tooling and manufacturing challenges of ramping up composites fabrication operations to efficiently meet the demands of a challenging and promising new marketplace.
About National Composites Week
The goal of National Composites Week (NCW) is to celebrate and bring attention to the ways that composite materials and composites manufacturing contribute to the products and structures that shape the American manufacturing landscape today.
NCW takes place each year in the final week of August and celebrates a specific theme.
The 2024 theme was Composites Reinvent the World. See what companies and individuals shared on LinkedIn and read more from the CW editorial team:
Related Content
The potential for thermoplastic composite nacelles
Collins Aerospace draws on global team, decades of experience to demonstrate large, curved AFP and welded structures for the next generation of aircraft.
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Automated robotic NDT enhances capabilities for composites
Kineco Kaman Composites India uses a bespoke Fill Accubot ultrasonic testing system to boost inspection efficiency and productivity.
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Composites manufacturing for general aviation aircraft
General aviation, certified and experimental, has increasingly embraced composites over the decades, a path further driven by leveraged innovation in materials and processes and the evolving AAM market.
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Combining multifunctional thermoplastic composites, additive manufacturing for next-gen airframe structures
The DOMMINIO project combines AFP with 3D printed gyroid cores, embedded SHM sensors and smart materials for induction-driven disassembly of parts at end of life.
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How are you celebrating National Composites Week?
The composites industry will be shining a light on the importance of composites this Aug. 26-30, 2024. Save the date, and help us promote how #CompositesReinventTheWorld.
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All-recycled, needle-punched nonwoven CFRP slashes carbon footprint of Formula 2 seat
Dallara and Tenowo collaborate to produce a race-ready Formula 2 seat using recycled carbon fiber, reducing CO2 emissions by 97.5% compared to virgin materials.
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Composites end markets: New space (2025)
Composite materials — with their unmatched strength-to-weight ratio, durability in extreme environments and design versatility — are at the heart of innovations in satellites, propulsion systems and lunar exploration vehicles, propelling the space economy toward a $1.8 trillion future.
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