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.

National Composites Week 2025: Space
Space

National Composites Week 2025: Space

Commemorating the theme “Performance With Purpose,” CW has gathered key stories over the last year that exemplify how composites have progressed space exploration and satellite programs.

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Latest Aerospace Articles

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Defense

Electroformed barrier technology hits project milestones, use case potential

Under the LEEF project, leading edge protection layer for composite structures developed by Ultima Forma and Polar Technology is being considered for eVTOL/UAV rotor and propeller blades, aerofoils and outlet guide vanes.

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Defense

Aerodine Composites expands composite propeller capabilities

Mission-tailored propellers for unmanned platforms including drones and UAS/UAVs are built for reliability, stealth and adaptability.

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Aerospace

Safran chooses France for next carbon brake production facility

The 2030 site will enable a gradual increase in aircraft carbon brake production volumes of 25% by 2037, backed by automation tech and environmental commitments.

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Aerospace

Spirit enters definitive agreement with CTRM for Malaysia facility, businesses

Acquisition transaction entered into previously announced merger agreement will make Composites Technology Research Malaysia (CTRM) an important asset to Boeing and Airbus programs.

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Filament Winding

UniSQ, iLAuNCH Trailblazer program drive digital twin innovation for composite repairs

Working with Boeing Australia, Memko and Dassault Systèmes, the University of Southern Queensland (UniSQ) has developed a digital twin via the 3DEXPERIENCE platform, digitizing processes that could lead toward more efficient and effective maintenance, repair and operations of future fleets.

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Next-gen fan blades: Hybrid twin RTM, printed sensors, laser shock disassembly

MORPHO project demonstrates blade with 20% faster RTM cure cycle, uses AI-based monitoring for improved maintenance/life cycle management and proves laser shock disassembly for recycling.

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Latest Aerospace News And Updates

Aerospace

FACC achieves 10.6% revenue growth in H1 2025 amid aerospace supply chain challenges

Revenue was increased to €484.7 million and a positive €18.4 million EBIT maintained, driven by strong business jet demand, global expansion of FACC’s production network and early results from its efficiency program.

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Hi-Temp Resins

Registration opens for CW Tech Days: High-Temperature Composite Solutions

CW Tech Days: High-Temperature Composite Solutions for Defense and Space Applications will take place Oct. 16, 2025.

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CAMX

Material solutions reduce critical weight, address challenges for aircraft development

CAMX 2025: Greene Tweed highlights lightweight composite innovations such as Xycomp DLF for aerospace and advanced air mobility.

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Hydrogen Storage

AMSL Aero secures $3 million to progress Australian LH2 aviation

Project goals include designing LH2 refueling systems, validating power distribution and fuel measurement in flight, and gathering evidence to support future national regulatory frameworks.

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Scaled Composites Model 437 aircraft to be flown for Beacon autonomy testbed

Northrop Grumman subsidiary part of Digital Pathfinder development of stealth aircraft with wings using continuous carbon fiber additive manufacturing and determinate assembly.  

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Defense

Piasecki launches Kargo II UAV featuring triple payload capacity

Payload, drivetrain and performance enhancements will support a range of military and commercial missions.

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Featured Posts

Defense

National Composites Week 2025: Aviation and AAM

Commemorating the theme “Performance With Purpose,” CW has gathered key stories over the last year that exemplify how composites have progressed aviation, AAM and defense.

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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.

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Post Cure

Post Cure: Composite seaglider craft redefine coastal transportation operations

The Viceroy all-electric flagship seaglider being developed by REGENT Craft in Rhode Island operates exclusively over water.  

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Core

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.

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Carbon Fibers

Revolutionizing space composites: A new era of satellite materials

A new approach for high volumes of small satellite structures uses low-CTE, low-cost CFRP cellular core, robust single-ply skins and modular panel systems to cut lead time, labor and cost for reflectors, solar arrays and more.

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Editorial

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.

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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