Composites reinvent aerospace, AAM and space

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

• Composite aerostructures in the emerging urban air mobility market

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.

• Plant tour: Joby Aviation, Marina, Calif., U.S.

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.

• Aviation-specific battery system uses advanced composites to address electric, hybrid flight

BOLDair’s composite enclosure, compression structures and thermal runaway management enables high-performance electric energy storage.

• CW Tech Days: Composites in advanced air mobility

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.