Future materials

A new generation of advanced aerospace concepts

Future materials

Researching cutting-edge new materials

EXCITING POSSIBILITIES

The materials behind future advanced concepts must be more durable, lightweight and cost-efficient than ever before. Airbus is exploring their potential with a focus on sustainability, circularity and digitalisation.

Unlocking the potential of tomorrow’s materials

Over recent decades, the aerospace industry has developed a range of materials to support novel concepts and product platforms. These range from metals, ceramics and coatings to composites. 

However in terms of materials, improvements for the next generation of aircraft are more likely to originate in improved sourcing and circularity to counter resource scarcity; and less energy-intensive production methods.

Looking towards a future of lower-carbon aviation, materials development at Airbus is focused on sustainability and digitalisation of materials. 

Material management

Sustainability

Minimising resource use and optimising the disposal of materials can help mitigate a product’s carbon footprint across its lifecycle. This improves its overall environmental impact.

When possible, materials should be bio-sourced, REACH* compatible, and respect guidelines for the sourcing of critical raw materials. Material circularity is important for composites, thermoplastics and aluminium in particular.

*Registration, Evaluation, Authorisation and Restriction of Chemicals (European Union regulation)

Digitising the materials domain brings major benefits

Adaptability: In a fast-changing world, adaptability depends on access to data to adjust product design in the face of new regulations, materials shortages or geopolitical uncertainty.

Ways of working: A leaner, connected organisation presents a competitive advantage. Data continuity results in high quality parts and full materials tracking, traceability and conformity. 

Digital twins: These virtual carbon-copies of our products evolve with the aircraft. They are dynamic, responsive and interactive, and essential at every stage of the product lifecycle from procurement to operation.

Digital twins are used to develop new aircraft. Their modelling capabilities inform design choices, enabling Airbus to select the most sustainable configuration and materials with the lowest possible environmental impact.  

Powerhouse computing: Quantum has the potential to model materials behaviour at the molecular level. For example, it is capable of modelling corrosion inhibition processes. This in turn will enable us to accurately design coatings that stand surface degradation to a far greater extent.  

Research areas

Natural fibres

Natural fibres can be obtained from plants and minerals. Lightweight and high-strength, they have a variety of applications including secondary, non-critical aircraft structures.

Future-materials-Flax

Bio-sourced resins

These resins derive some or all of their constituent monomers from biological sources, for example sugarcane or lignin. Their use could provide an alternative to phenolics (a class of resin) in aircraft. Research areas include furan, epoxy and polyamide.

Future-materials-Bagasse

Biomass carbon fibre

These fibres are created by carbonising precursors obtained from biomass derived from raw materials. Their use in bio-composites could result in composite materials that provide a viable alternative to carbon fibres obtained from oil-based precursors. Research areas include algae.

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Hydrogen
The MultiFunctional Fuselage Demonstrator (MFFD)

Thermoplastics

Our research areas

Thermoplastic polymers present a weight advantage over carbon composites, which are used to build major aircraft components. They are easier to recycle and repurpose, and their production is less energy-intensive than carbon fibre composites.  

To explore thermoplastics' potential, Airbus has participated in the Multi Functional Fuselage Demonstrator (MFFD) consortium. It was developed as part of the EU’s Clean Sky 2 public/private funding programme.

In production terms, thermoplastic composites enable fuselage sections to be assembled using novel methods.

A secondary goal of the MFFD is to investigate enablers for thermoplastic composite fuselage barrel production at a rate of between 60 and 100 aircraft per month. 

Our research areas

End of life and circularity

Airbus has identified three materials that are important to circularity and improving end-of-life management. We are adopting innovative techniques to recycle these materials from our industrial production and at end-of-life.

Tarmac Aerospace

Raw material management

It is is organised along three axes:

Material inflow: materials used to manufacture aircraft
Material reuse: reusing production waste
Material outflow: end-of-life management

Material-services.jpg

Composites

Composite recycling is challenging. At Airbus, it is the subject of research into how carbon fibres can be separated from resin for reuse.

Composite carbon fiber weaving machine

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