How Material Selection Can Advance Aerospace Efficiency

For over 30 years, Aerospheres has been a trusted partner in the aerospace industry, supplying high-quality materials and innovative solutions to meet the evolving needs of engineers worldwide. As the aviation sector continues to prioritise efficiency and sustainability, material selection in aircraft design and maintenance is incredibly important.

In this article, we’ll explore how the right materials can revolutionise aerospace efficiency and performance, while contributing to a sustainable future.

Why Material Selection Matters 

Material selection is the foundation of aircraft design and maintenance, directly influencing performance and safety. After all, aircraft must meet rigorous demands, including operating reliably in extreme conditions while maintaining durability over their service life.

Reducing an aircraft’s weight significantly lowers fuel consumption, cutting costs and carbon emissions. Advanced materials like composites allow engineers to replace traditional materials without sacrificing performance.

Lighter aircraft are more fuel efficient, enabling airlines to reduce their environmental impact. Advanced composites such as carbon fibre-reinforced polymer (CFRPs) are particularly advantageous because they provide superior strength-to-weight ratios compared to conventional materials like aluminium or steel.

What Are Advanced Composites?

Advanced composites are engineered materials that combine two or more substances to create superior properties. For engineers, advanced composites offer a unique opportunity to achieve lighter, stronger and more versatile designs. In aerospace applications, the most common composites include:

Carbon fibre-reinforced polymers (CFRPs) - Known for exceptional strength-to-weight ratios.

Glass fibre-reinforced polymers (GFRPs) - Offering cost-effective solutions for specific applications.

Hybrid composites - Blending materials for added versatility in demanding environments.

These materials excel in areas where traditional metals fall short, such as corrosion resistance. 

Aircraft like the Boeing 787 Dreamliner utilise composites extensively in their design. These innovations result in weight reductions of up to 20% compared to earlier models, translating into significant fuel savings and lower CO2 emissions. 

Smart Materials

Smart materials are redefining possibilities in aerospace design and maintenance. Unlike conventional materials, smart materials can adapt their properties - such as shape, stiffness or viscosity - when exposed to external stimuli like heat or pressure.

In the aviation industry, one example of such innovative materials is shape memory alloys (SMAs). These alloys can return to their initial shape after being deformed, making them valuable for applications such as self-healing components.

3D Printing

3D printing is revolutionising the manufacturing of aircraft components by enabling the production of intricate, lightweight designs that traditional methods cannot achieve.

This technology minimises material waste and facilitates the creation of components with superior performance characteristics. For instance, 3D-printed parts can incorporate internal lattice structures that maximise strength while keeping weight to a minimum. 

3D-printed components are already being used in engines, brackets and airframe structures, delivering superior performance while reducing production costs.

Challenges in Material Selection

Cost Concerns

Advanced composites often involve higher upfront costs. However, their long-term advantages, including reduced fuel consumption and extended service life, make them a sound investment for forward-thinking engineers.

Manufacturing and Repair Considerations

Working with composites requires specialised techniques such as autoclaving and resin infusion. Additionally, repair processes demand advanced skills, including damage assessment and precision bonding. Aerospheres supports engineers with expert guidance and high-quality materials to overcome these challenges efficiently.

Material Selection and Sustainability

As the aviation industry commits to net zero emissions targets, sustainable material selection is becoming increasingly critical. Innovations such as bio-based composites and hybrid designs are enabling engineers to reduce environmental impact while maintaining high performance.

Recycling Composites

Efforts to develop effective recycling methods for composites are gaining traction. Technologies like pyrolysis and solvolysis are enabling the recovery of valuable fibres and resins, reducing waste and supporting circular manufacturing practices.

Hybrid Materials for Green Aviation

Hybrid materials that combine lightweight composites with metallic elements are emerging as a solution for applications requiring added durability or heat resistance. These materials balance performance with environmental considerations, making them a popular choice for next-generation aircraft.

Choose Aerospheres

For engineers looking to acquire high-quality aerospace materials quickly and reliably, we are your ideal partner. With over three decades of experience, we have built a reputation as a trusted global supplier committed to advancing aerospace efficiency and sustainability.

To find out more about our comprehensive services, and how we can support your operations, please get in touch. As your one-stop shop for aircraft maintenance, we’re ready and waiting to help you choose the right materials to suit your needs.