Airbus, Boeing eye fast output as plastics loom for future jets

In the high-stakes world of aerospace, Airbus and Boeing are gearing up for a new era of jet production, one that promises to be faster, more efficient, and potentially more environmentally friendly. The two giants are exploring the use of novel materials like thermoplastics, which could revolutionize the way aircraft are built and operated. But as they race to increase output to unprecedented levels, the question remains: can they navigate the challenges of supply chain disruptions and engine development delays to deliver on their ambitious plans?



The current landscape is fraught with challenges. Weak supply chains and lengthy waits for engine developments have pushed back the launch of projects to replace the decades-old Boeing 737 and Airbus A320 series. Despite the high demand for these jets, both companies are years away from launching their next-generation models. This delay is a stark reminder of the systemic risks that come with relying on complex global supply chains and cutting-edge technology.

But Airbus and Boeing are not sitting idly by. They are actively researching new materials and manufacturing techniques to mitigate these issues. Randy Wilkerson, who represents Boeing in a NASA research project for high-capacity manufacturing called HiCAM, stated, "The goal is to recommend the best approach to transition...(to) the next airplane programme." This strategic focus on innovation and efficiency is a clear response to the current challenges.

One of the most promising developments is the use of thermoplastics. Unlike traditional thermoset composites, which maintain their shape and toughness once cured in autoclaves, thermoplastics can be reheated and remoulded to produce a single, flowing aerodynamic shape. This flexibility offers significant advantages in terms of weight reduction and production efficiency. Lukas Raps of the German Aerospace Centre DLR noted, "You can melt it and reshape it in any way you like." This adaptability is a game-changer for an industry that has long relied on time-consuming and energy-intensive manufacturing processes.

The potential benefits of using thermoplastics and other novel materials are clear. Lighter aircraft mean improved fuel efficiency and reduced emissions, which is a win for both the environment and the bottom line. But there are also drawbacks. The shift to welding rather than physical titanium fasteners on structural parts could face certification hurdles, and the industry is still grappling with the challenges of scaling up production to meet the demand for much larger numbers of small jets.



Despite these challenges, both planemakers are telling the composites industry they want to be ready for production speeds as high as 100 jets a month each. This blistering pace, equivalent to one roughly 200-seat jet every few hours, underscores their commitment to scaling up production despite current challenges. York Roth, a leading researcher at Airbus in Germany, emphasized, "There (is) no doubt that thermoplastic materials offer opportunities that we don't have with thermoset." This strategic shift towards more adaptable and efficient materials is aimed at preparing for future growth and meeting the demands of a rapidly changing industry.

But as Airbus and Boeing race to increase output, they must also consider the broader implications of their actions. The use of novel materials and advanced manufacturing techniques could have significant environmental and economic impacts, and the industry must be prepared to address these challenges head-on. The next generation of jets may be faster and more efficient, but they must also be sustainable and responsible if they are to truly revolutionize the aerospace industry.

In conclusion, the future of jet production is poised for a major transformation, driven by the use of novel materials and advanced manufacturing techniques. But as Airbus and Boeing race to increase output, they must also consider the broader implications of their actions and work to address the challenges that lie ahead. The next generation of jets may be faster and more efficient, but they must also be sustainable and responsible if they are to truly revolutionize the aerospace industry.