What are the best ways for the aviation industry to develop new materials and manufacturing processes?

1 Why innovate?

The main drivers for innovation in the aviation industry are the increasing demand for air transport, the rising environmental and social pressures, and the fierce global competition. The industry needs to find ways to reduce fuel consumption, emissions, noise, and waste, while enhancing safety, reliability, and customer satisfaction. Moreover, the industry needs to cope with the changing market conditions, customer preferences, and regulatory frameworks. Innovation can help the industry achieve these goals by creating new value propositions, reducing costs, and increasing differentiation.

2 What are the new materials?

The new materials that the aviation industry is developing and using include composites, metals, ceramics, and polymers. Composites are materials that combine two or more different components, such as carbon fiber reinforced plastics (CFRP), which are lighter and stronger than conventional metals. Metals are materials that have been modified or alloyed to improve their properties, such as titanium, aluminum, and steel. Ceramics are materials that are made from inorganic compounds, such as silicon carbide, which are resistant to high temperatures and corrosion. Polymers are materials that are made from organic molecules, such as plastics, rubber, and foam, which are flexible and durable.

3 How are they manufactured?

The new materials require new manufacturing processes that can produce them efficiently, accurately, and reliably. Some of the new manufacturing processes that the aviation industry is using or exploring include additive manufacturing, digital manufacturing, and smart manufacturing. Additive manufacturing, also known as 3D printing, is a process that builds objects layer by layer from a digital model, which can reduce waste, increase customization, and enable complex geometries. Digital manufacturing is a process that uses digital technologies, such as sensors, software, and data, to optimize the design, production, and operation of products and systems, which can improve quality, productivity, and flexibility. Smart manufacturing is a process that integrates physical and cyber systems, such as robotics, artificial intelligence, and internet of things, to automate and coordinate the manufacturing activities, which can enhance efficiency, agility, and innovation.

4 What are the benefits?

The new materials and manufacturing processes can offer a range of advantages to the aviation industry and its stakeholders, such as enhanced aerodynamics, structural integrity, and functionality of the aircraft and aerospace systems. This can lead to increased speed, range, capacity, and durability. In addition, the weight, fuel consumption, emissions, noise, and waste of the aircraft and aerospace systems can be reduced, helping to comply with regulatory standards. All of this can create new value propositions, reduce costs, and increase differentiation for the aviation industry and its customers. This can help to increase their market share, profitability, and reputation.

5 What are the challenges?

The new materials and manufacturing processes in the aviation industry come with many challenges, such as high investment, complex testing, and difficult adoption. These challenges require significant upfront and ongoing investment in research and development, infrastructure, equipment, and workforce. Additionally, the new materials and manufacturing processes must go through rigorous testing and validation to ensure safety, reliability, and compatibility with existing systems. Furthermore, the industry must overcome technical, organizational, and cultural barriers to adoption and implementation. All of these issues can be risky, costly, time-consuming, and resource-intensive for the industry and its partners.

6 How to succeed?

The aviation industry can succeed in developing and implementing new materials and manufacturing processes by adopting some of the best practices and strategies, such as collaborating with other stakeholders to share knowledge, resources, and expertise; innovating by fostering a culture of creativity, experimentation, and learning; and adapting to changing market conditions, customer preferences, and regulatory frameworks. Leveraging the opportunities offered by digital technologies like data analytics, simulation, and automation can also help the aviation industry to stay ahead of the curve. Furthermore, embracing the diversity, complexity, and uncertainty of the new materials and manufacturing processes is key to achieving success.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?