Composites Use in Aerospace

The advantages of building aircraft structures with composites, compared to metal, include light weight, high specific strength, superior fatigue properties, damage tolerance and the absence of corrosion.

A return to the Space Symposium: Charting the next frontier
Editorial

A return to the Space Symposium: Charting the next frontier

Since 2019 the space sector has been on a rapid upward trajectory. This year’s Space Symposium delivered that same optimism, celebrating the community’s continued proliferation, even as political and financial uncertainty raise new questions.

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Latest Aerospace Articles

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Aerospace

Spirit AeroSystems signs divestiture agreement with Airbus

Per the definitive agreement, Airbus is taking ownership of assets across seven of Spirit’s sites to ensure stability of its supply for its commercial aircraft programs.

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Defense

Call for abstracts: CW Tech Days to explore high-temperature composite solutions

The fall 2025 installment of CW’s Tech Days online event series will cover high-temperature composite solutions for defense and space applications.

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Aerospace

Gulfstream G800 earns FAA, EASA certifications

Final certifications for the ultra-long range, high-speed composites-intensive business jet have confirmed longer range, higher cruise speeds and shorter takeoff and landing distances than previously expected.

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Carbon Fibers

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.

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Aerospace

OVERLEAF webinars share composite LH2 innovations, results

A series of three webinars presented by OVERLEAF project partners explore how it is achieving a novel low-pressure, LH2 storage system architecture through LCA methodologies, optical hydrogen sensors and cryogenic-ready 3D printing and materials.

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Aerospace

Embraer presents FACC with Supplier Award 2025

The 20-year partnership is reinforced by current projects in the field of aerospace, AAM, sustainability and composites.

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Knowledge Centers

Design, Simulation and Testing Technologies for Next-Gen Composite Structures
Design, Simulation and Testing Technologies for Next-Gen Composite Structures

Review the state of the art in design, simulation, failure analysis, digital twins, virtual testing and virtual inspection.

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Composites in Infrastructure and Construction
Composites in Infrastructure and Construction

ÂÌñÏ×ÆÞ’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.

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Latest Aerospace News And Updates

Aerospace

Venus Aerospace makes headway on scaling RDRE hypersonic engine

More compact and agile hypersonic rocket engine propulsion system, supported by a NASA SBIR, will be demonstrated in the summer.

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Aerospace

FANTOM project forms basis for automated aerocomposite NDT

Three-year collaboration between IRT Jules Verne and partners achieves roboticized platform that meets efficiency and flexibility challenges of large composite parts inspection.

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Thermoplastics

Diehl Aviation matures recyclable composite Eco Bin

Overhead baggage compartment using only fiber-reinforced thermoplastics, metal hardware and no adhesives wins Crystal Cabin Award, supports circular aircraft interiors.

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Aerospace

Demgy Group grows aircraft interior expertise with Tool-Gauge acquisition

Tool-Gauge, a key U.S. supplier of unreinforced and reinforced plastic components and subassemblies for Boeing and Airbus, adds to Demgy Group’s global footprint.

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Carbon Fibers

JetZero announces Collins Aerospace nacelles, new campus and use of fiber optic sensors

California startup continues push toward first flight of its blended wing body (BWB) demonstrator aircraft in 2027, which uses carbon fiber composite fuselage, wings.

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Fastening

Daher celebrates Shap’in anniversary, highlights R&D developments

Two years after its launch, Daher’s technology center has been actively pursuing its ambitions to mature aerocomposites, from thermoplastics welding to rethinking their entire life cycle.

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Featured Posts

Addressing rivet hole drilling challenges for aerospace composites

Kennametal explores technological advancements in composite drilling, including stacked laminates, to meet aerospace applications and sustainability challenges.

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Aerospace

JEC World 2025 highlights: Trends in aerospace, new space and defense

CW editor-in-chief Scott Francis discusses trends in aerospace on display at JEC World — as the composites industry awaits a new single aisle aircraft program, the industry puts continued focus on new space, defense, UAM.

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Defense

The AAMMC Tech Hub: Ramping U.S. production of large thermoplastic composite aerostructures

CW talks with Syensqo, Spirit AeroSystems and other consortia members about current funding, specification of the next world’s largest press, organizational structure and projects to support U.S. companies in the race to deliver >40,000 sustainable and efficient aircraft over the next 20 years.

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Post Cure

Post Cure: Defect-free RTS sets new standards for curved composite structures

Rapid Tow Sheering (RTS), commercialized by iCOMAT, enables in-plane shearing of tows to steer fibers, eliminating concern of buckled tows and wrinkles.

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Electronics

Plasma moves beyond improved bonding to coatings, multifunctional composites

Plasmatreat cold plasma systems clean, activate surfaces and apply nanocoatings for dielectric barriers and more.

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Welding

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

ÂÌñÏ×ÆÞ 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. 

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FAQ: Aerospace

How are composites used in aerospace structures?

Since the 1950s*, composites have been growing in use in commercial and defense aircraft, ranging from struts and tail components, to wing skins and fuselages, to engine components and propeller blades.

One of the largest challenges to adoption of composites by the aerospace industry is stringent standards especially for safety critical structures, necessitating time- and labor-intensive processes to qualify new materials for use on passenger aircraft.

Qualified and well-tested autoclave-cured carbon fiber and thermoset-based prepregs are most often used for many structures, though other materials and formats, including thermoplastic tapes, are also in development or use.

Source: The FAA: Keeping up with aerocomposites evolution

*In the 1950s, Boeing began using fiberglass in its 707 passenger jets, and at the time the material made up about 2% of the overall aircraft by weight. Since then, Boeing, Airbus and other aircraft manufacturers have continued to increase this percentage with successive aircraft models. Today’s twin-aisle commercial aircraft such as the Boeing 787, first launched in 2009, and the Airbus A350 comprise approximately 50% composites by weight, largely carbon fiber-reinforced polymer (CFRP).

How are composites used in space structures?

At the time the Apollo capsule, which landed on the moon in 1969, was built by NASA, composites industry was still in its infancy and the materials were not yet in widespread use, though the Apollo capsule used early composite technology in the form of an ablative heat shield made from Avcoat, an epoxy novolac resin with silica fibers in a fiberglass-phenolic honeycomb matrix. A fiberglass honeycomb was bonded to the primary structure and the paste-like material was injected into each cell individually.

Since Apollo, advanced composites have evolved by leaps and bounds, and have played a significant role in space programs with use in launch vehicles, the space shuttle, satellites, space telescopes and the International Space Station.

Source: Composites in the race to space