High-performance plastics in aerospace
Learn how high-performance plastics are changing aerospace. Discover benefits, applications & future potential.
The requirements for materials in aerospace are among the strictest in the entire industry. Lightweight construction, temperature resistance, flame retardancy and long-term stability under extreme conditions are essential properties that modern materials must fulfil. In this context, high-performance plastics and aviation plastics have established themselves as indispensable materials. This case study examines how they are used in modern aircraft and aerospace systems and what advantages they offer over traditional materials such as metal.
Requirements for materials in aviation
The aviation industry faces the challenge of reducing weight without compromising safety. Every kilogram saved means lower fuel consumption and lower operating costs. At the same time, the materials used must neither corrode nor fail under temperature fluctuations.
The most important material requirements include:
- Low weight with high mechanical strength
- Resistance to high and low temperatures
- Flame-retardant properties
- Good chemical resistance and UV stability
- Easy processing and reproducibility
High-performance polymers as the material of choice
High-performance polymers such as PEEK, PEI or PPS are now standard in many aviation-specific applications. They are characterised by an excellent property profile and can be processed in a variety of ways. Particularly in cabin construction, in line systems and structural components, they are increasingly replacing aluminium or titanium.
Typical high-performance polymers in aviation
| Polymer | Properties | Applications |
|---|---|---|
| PEEK (polyetheretherketone) | High temperature and chemical resistance, very good mechanical strength | Fasteners, cable insulation, bearings |
| PEI (polyetherimide) | Very good flame retardancy, high dimensional stability | Interior panelling, ventilation systems |
| PPS (polyphenylene sulphide) | Extremely chemical-resistant, good creep resistance | Sealing systems, electronic housings |
Practical example: use of PEEK in the aircraft cabin
A manufacturer of passenger aircraft specifically used PEEK to replace fasteners for seat systems. The aluminium parts previously used were stable, but heavy and susceptible to corrosion.
Results of the material change:
- Weight reduction of 60 %
- Saving of approx. 100 kg per aircraft
- Maintenance interval extended by 30 %
- Improved recycling rate of the components
This change shows how targeted use of materials with high-performance plastics not only brings technical advantages but also makes economic sense.
Advantages of aviation plastics over metals
High-performance plastics offer several advantages in aerospace at once:
- Reduced weight: Plastics weigh significantly less than metal and thus help to lower kerosene consumption.
- Corrosion resistance: Unlike metals, they do not require complex coating or maintenance.
- Design freedom: Complex geometries can be realised more easily.
- Simplified assembly: Plastic parts are often quicker and more cost-effective to assemble.
Future prospects for high-performance plastics in space travel
High-performance plastics are also becoming increasingly important in space travel. In addition to classic requirements such as weight and temperature, radiation resistance and outgassing behaviour also play a major role here. Materials such as PBI (polybenzimidazole) or PTFE (polytetrafluoroethylene) are used, for example, in satellite housings, insulation materials or fuel systems.
Important trends:
- Additive manufacturing with high-performance plastics
- Material combinations (multi-material construction)
- Function integration (e.g. sensors in the component)
Conclusion
Aviation plastics are far more than just an alternative to metal. They are a central component of modern lightweight construction strategies in aerospace. High-performance polymers such as PEEK or PEI not only offer weight and cost advantages, but also impress with their versatility, durability and future viability. The combination of technical performance and economic efficiency makes them a key element for the mobility of tomorrow.
