Take Greene Tweed’s high-performance compression-moulded, random discontinuous long-fibre (DLF) thermoplastic composite, Xycomp, for example. It is replacing metals and thermoset composites in more and more complex-shaped product solutions for crew and passenger seating, galley, overhead bin compartment doors, brackets, fittings, and attachments for business and commercial airplanes, military aircraft, helicopters, and eVTOLs. More than 400,000 DLF components, including interior parts with complex contour shapes with moulded-in features, are currently in service across 12 commercial aircraft platforms.
Here are the three key reasons why aircraft manufacturers are upgrading to thermoplastic composites, such as XycompDLF:
Travel Lighter
Thermoplastic composite materials, such as Xycomp, offer exactly what an aircraft interior needs: A high strength-to-weight ratio. “This means that the interior components made from Xycomp provide the same or better strength as metal components while being significantly lighter,” explains Travis Mease, product manager of structural components at Greene Tweed, “It offers superior resistance to fatigue, vibration, and impact, while providing up to 50 percent weight savings over traditional metallic parts.”
This lightweighting of interior components improves fuel efficiency, lowering operational costs and increasing payload capacity. That’s not all. “Airlines and aircraft manufacturers are trying to reduce their emissions and make air travel more sustainable. Xycomp interiors help our customers reduce their carbon footprint and meet environmental regulations,” says Kele Jurkoshek, industry expansion manager for aerospace & defense at Greene Tweed.
Enable Cost-Effective Production
Not only do interior components made of thermoplastic composites last longer, but their production process is more efficient and reduces waste.
Traditionally, aircraft interior parts have been manufactured by machining away material from metal billets or bars and, in this process, a significant part of the raw materials goes to scrap. “Xycomp reduces this waste because its buy-to-fly ratio - the ratio of material purchased to final part output that ultimately ends up in flight - is much lower than metals. This means that even if the thermoplastic composite material costs more than the metal it replaces, it will result in savings because more material will make it to the air,” says Travis.
Tested and Approved
Thermoplastic composite components in the interiors of an aircraft don’t just solve some of the toughest lightweighting challenges but they also meet flame, smoke, toxicity (FST) standards and 15-minute burn-through requirements without needing any additional treatments. “These lightweight materials can withstand extreme temperatures, pressures, and corrosion related to flight conditions, while still complying with FST requirements,” sums up Kele.
