Thermoplastics

Thermoplastic composites combine specific properties which make them highly suitable for aerospace structures. Low weight designs are achieved through inherent material toughness and excellent fire safety properties. At the same time, low-cost processing is obtained by using manufacturing processes like thermofolding, press-forming, welding and co-consolidation. Also, manufacture without clean rooms or freezer storage results in lower costs. Examples of the flexibility of thermoplastics are:

Thermofolding of floor panel edges (Gulfstream G450, G550, G650) rudder trailing edges (Gulfstream G450, G550, G650)
Press-forming of panels (Boeing Apache) and ribs (Gulfstream G450, G550, G650, Airbus A340-500/600, A380)
Welding of assemblies (Airbus A340-500/600 and A380, Gulfstream G650)
Co-consolidation of stiffened panels and beams. An example is a sine wave beam, where the connection between web and caps is normally difficult in composites. In thermoplastics, it is simplified by a butt joint. This type of joint is not possible with other composites.

The feasibility of thermoplastics technology has been proven through a growing number of production applications. Since the early 1990’s, Fokker has invested in thermoplastics technology and obtained a leading position in this field. Subsequent technology projects have been supported by the Dutch Ministry of Economic Affairs. Fokker Aerostructures works together closely in its projects with customers, suppliers and renowned institutes and Universities.

Resistance welding of A380 J-nose	Induction welding of G650 rudder
Sine wave beam, with butt jointed web	Cross-section of a thermoplastic butt joint