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As  (NCW) unfolds this year and we discuss the myriad ways in which composites exemplify “Performance With Purpose,” one of the first areas that demands attention is the use of composite materials in the aerospace and advanced air mobility (AAM) sectors. Often innovations in materials are driven by the demands in this sector, are proven out in the qualification of prototypes and pushed to their limits in defense applications as part of their pathway toward commercialization. Today, new innovations aimed at manufacturing for scale, including ever-evolving automation solutions are propelling the industry forward.

A central theme echoed in recent ��ñ���� reporting — including CW’s coverage of this year’s Paris Air Show — is the industry’s decisive shift toward high-rate production. Demand for commercial airliners is a driving force behind a trend where aerospace manufacturers are increasingly integrating automation, robotics and digital process controls to boost output, repeatability and precision. Advances in automated fiber placement (AFP), stamp forming and in-line inspection systems, and the growing use of thermoplastic composites (TPCs) and ultrasonic welding is helping cut cycle times and scale composite manufacturing to levels more closely aligned with metal-intensive assembly lines. While thermoset composites continue to be widely used in aerospace applications, TPCs are gaining traction for their recyclability, toughness and production efficiency — qualities that align well with the aerospace sector’s goals for sustainability and volume manufacturing.

Rising to the challenge of passenger growth and fleet modernization, OEMs are envisioning next-generation single-aisle airliners that blend efficient aerodynamics, lightweight structures and modular composites. Coverage during industry showcases — like those at the Paris Air Show — highlight OEMs and suppliers exploring the use of composites for new wing designs, structural parts and composite-intensive fuselages that cut weight without compromising strength.

Meanwhile, emerging from the AAM realm, vertical take off and lift (VTOL) programs — though still in prototype stages — are already serving as experimental platforms for high-rate composite production. This new emerging class of aircraft offers new insights into workflow optimization, tooling reusability and scale-up strategies. As these programs move toward certification and potentially small-scale production, the lessons learned — particularly in balancing structural complexity with manufacturability — will cross-pollinate back to traditional aerospace programs scaling to meet commercial airline demand.

NCW provides a fitting moment to reflect on all of this progress. Automation isn’t optional — it’s driving production rates to meet the demand for these applications. Thermoplastic composites aren’t niche — they’re increasingly vital to scalable, sustainable aerospace systems. Next-generation single-aisle platforms continue to serve as the proving ground for composite-driven design and manufacturing. VTOL efforts aren’t just flying taxis — they’re laboratories for next-level composite production.

Together, these themes encapsulate a dynamic era — one in which composite materials and production innovation coalesce to help redefine aerospace manufacturing. This year’s NCW is a great time to reflect on some of the progress we’ve seen in the aerospace sector this year. Below is a roundup of key content to explore, read and learn more.

Note: Below covers only articles produced in 2025 for these topics. For other related content (including news and products), visit these sections of our website.

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Paris Air Show highlights advanced materials, industry momentum

This year’s international air show offered a glimpse of the rapidly expanding future for composites in aerospace.

What you might have missed at Paris Air Show 2025

A surge in defense spending, partnerships in hydrogen propulsion and new combat aircraft agreements, many backed by composites industry leaders, culminated the 55th Paris Air Show.  

Ceramic matrix composites: Faster, cheaper, higher temperature

New players proliferate, increasing CMC materials and manufacturing capacity, novel processes and automation to meet demand for higher part volumes and performance.

Cutting 100 pounds, certification time for the X-59 nose cone

Swift Engineering used HyperX software to remove 100 pounds from 38-foot graphite/epoxy cored nose cone for X-59 supersonic aircraft.

Clean Aviation Pax Cabin Demonstrator uses biocomposites to cut weight, environmental impact

Full-scale regional aircraft fuselage equipped with cabin structures and systems demonstrates next-gen interiors to TRL 6 with successful FST, noise and vibration testing performance.

Advancing thermoplastic composite primary structure and morphing wings

The HERWINGT project in Clean Aviation seeks to ready technologies — including at least 16 composite demonstrators — for a hybrid-electric regional aircraft with 50% less fuel burn to be launched by 2035.

Aerospace prepregs with braided reinforcement demonstrate improved production rates, cost

A recent time study compares the layup of a wing spar using prepreg with A&P’s TX-45 continuous braided reinforcement versus traditional twill woven prepreg.

Inside the MFFD — CW's coverage of the Clean Aviation multifunctional fuselage demonstrator

CW rounds up coverage of the MFFD project over the past decade. Now complete, the MFFD illustrates numerous processes and technologies for manufacturing primary aerospace structures using thermoplastic composites. 

Plant tour: Collins Aerospace, Riverside, Calif., U.S. and Almere, Netherlands

Composite Tier 1’s long history, acquisition of stamped parts pioneer Dutch Thermoplastic Components, advances roadmap for growth in thermoplastic composite parts.

VIDEO: Installing the world’s largest thermoplastic composites press at Airbus Bremen

At JEC World 2025, Pinette PEI detailed its latest turnkey system for future aircraft serial parts production.

ASCEND program completion: Transforming the U.K.'s high-rate composites manufacturing capability

GKN Aerospace, McLaren Automotive and U.K. partners chart the final chapter of the 4-year, £39.6 million ASCEND program, which accomplished significant progress in high-rate production, Industry 4.0 and sustainable composites manufacturing.

Prepreg compression molding supports higher-rate propeller manufacturing

To meet increasing UAV market demands, Mejzlik Propellers has added a higher-rate compression molding line to its custom CFRP propeller capabilities.