The aerospace industry is undergoing a radical transformation, and at the heart of this evolution lies a material that was once overlooked but is now revolutionizing aircraft manufacturing—thermoplastics.
Both Boeing and Airbus, the undisputed titans of the aviation world, are turning their backs on traditional aluminum-heavy construction. In its place, they are embracing advanced thermoplastic composites that promise lighter aircraft, faster production cycles, increased fuel efficiency, and a potential reimagining of the way aircraft are built and maintained.
Why Now? The Pressure for Speed, Sustainability, and Scale
After the pandemic-induced slump, air travel is bouncing back faster than expected. Airlines across the world are placing massive new orders, and manufacturers are under intense pressure to meet delivery timelines.
- Airbus and Boeing are targeting monthly production rates of up to 80 aircraft by 2026.
- Industry insiders speculate both companies are exploring production targets of 100 aircraft per month in the long term.
This means one thing: traditional aluminum-heavy construction techniques aren’t fast enough anymore. They’re labor-intensive, involve lengthy curing times, and are less adaptable to automation.
Thermoplastics: The Game-Changer in Aerospace Engineering
What makes thermoplastics so revolutionary? Let’s break it down.
- Thermoplastics are lightweight, high-strength polymers that can be heated, reshaped, and cooled repeatedly without losing their structural integrity.
- Unlike traditional thermoset composites, thermoplastics don’t require lengthy curing processes.
- They can be welded instead of riveted, reducing assembly complexity and enhancing part integrity.
- Thermoplastics are fully recyclable, making them far more sustainable than aluminum and older composite materials.
Boeing and Airbus have already begun integrating thermoplastic components into new aircraft models. Doors, clips, brackets, and even parts of the fuselage are now being produced using these advanced materials.
How Thermoplastics Outperform Aluminum and Thermosets
Here’s a closer look at how thermoplastics compare to legacy materials:
| Property | Aluminum | Thermoset Composites | Thermoplastics |
|---|---|---|---|
| Weight | Moderate | Light | Very Light |
| Strength-to-Weight Ratio | Medium | High | Very High |
| Recyclability | Medium | Low | High |
| Production Speed | Slow | Moderate | Fast |
| Assembly Method | Riveting | Curing & Adhesives | Welding & Molding |
Thermoplastics can reduce component weight by up to 25% compared to aluminum, and that means millions in fuel savings per aircraft per year.
Boeing’s Strategic Shift: Betting on Automation and Speed
Boeing has made substantial investments in automated thermoplastic manufacturing facilities. Its focus is on:
- Reducing part count and complexity
- Automating fuselage and structural part production
- Improving modular assembly techniques
In its latest production updates, Boeing hinted at increased use of in-situ consolidated thermoplastics, a process that allows on-the-spot fusion of materials using heat and pressure—without adhesives or rivets.
Boeing believes this can slash production time by over 40% on key structures.
Airbus Goes Full Throttle: Thermoplastics in the A220 and Beyond
Airbus is taking an equally aggressive approach, integrating thermoplastics into the production of its A220 and A320neo families, with an eye on next-generation aircraft designs.
The European giant has:
- Partnered with Spirit AeroSystems and Daher for thermoplastic fuselage production
- Invested in automated tape-laying technology to produce large, integrated structural parts
- Focused on material uniformity, enabling consistent performance across aircraft in extreme weather and altitudes
Airbus says thermoplastics will play a critical role in achieving net-zero carbon emissions by 2050, thanks to their lower lifecycle footprint.
Fuel Savings and Environmental Impact
Let’s put this into real-world numbers:
- Every 1% reduction in aircraft weight leads to a 0.75% decrease in fuel consumption.
- A 25% weight reduction using thermoplastics can result in millions of gallons of fuel saved per aircraft annually.
- Thermoplastics require 50% less energy to produce than aluminum or thermosets.
For airlines, this translates to cheaper operations. For the planet, it means reduced CO2 emissions and a greener future for aviation.
Faster, Leaner Production: A Dream for OEMs
Boeing and Airbus both acknowledge one critical thing: aircraft production speed is the bottleneck. With demand surging, they must find ways to scale without compromising quality.
Thermoplastics enable:
- Shorter cycle times (no curing required)
- Welding instead of bolting, cutting assembly time
- Modular construction, allowing parts to be manufactured in parallel and snapped together like Lego blocks
According to a joint Airbus/Boeing study:
Thermoplastic fuselage components can be produced up to 3x faster than traditional aluminum or thermoset equivalents.
Cost Benefits for Airlines and Manufacturers
While thermoplastics are initially expensive to integrate, the long-term cost benefits are massive.
- Lower maintenance (less corrosion and fatigue)
- Fewer parts (up to 50% reduction in some components)
- Quicker turnaround times in manufacturing and repairs
Airlines can save over $2 million in maintenance and fuel over an aircraft’s lifetime using thermoplastic-enhanced components.
A Material for the Future: Aerospace to Space and Beyond
Thermoplastics aren’t just an aviation fad—they are now being explored for:
- Spacecraft interiors and exteriors (NASA is testing thermoplastic shielding)
- Urban Air Mobility (UAM), such as air taxis and eVTOLs
- Military drones and stealth jets, where lighter weight equals better maneuverability and range
Challenges Still Ahead
Despite all the upside, there are some hurdles Boeing and Airbus must overcome:
- Scaling up production capacity to meet thermoplastic demand
- Training aerospace engineers and workers in new manufacturing techniques
- Ensuring regulatory compliance with strict aviation safety standards
However, as more aircraft roll off assembly lines with thermoplastic parts, these challenges are quickly being met with new technologies and automation solutions.
The Market Is Responding
Aerospace suppliers are investing heavily in thermoplastic innovation:
- Solvay, Toray, and Hexcel, the biggest players in composite materials, have ramped up production of thermoplastic resins and fibers
- New joint ventures and R&D hubs are emerging across Europe and North America
Meanwhile, Wall Street is paying attention. Shares in thermoplastic material providers have risen significantly over the past 18 months, fueled by projections of massive aerospace adoption by 2030.
What Does This Mean for the Future of Flight?
Thermoplastics are not just a new material—they’re the key to unlocking the next generation of aviation. Here’s what we’ll likely see in the next decade:
- Fully thermoplastic fuselages for narrow-body and regional jets
- 3D printing of thermoplastic parts on-demand for spares and repairs
- Smart thermoplastic materials embedded with sensors for real-time monitoring
Conclusion
Airbus and Boeing aren’t just building planes—they’re redefining how we think about aircraft design, production, and performance.
By embracing thermoplastics, they are laying the foundation for:
- Faster production at unprecedented scales
- More sustainable aviation operations
- Lighter aircraft that consume less fuel and emit less carbon
- A manufacturing model ready for the automation age
The age of aluminum is fading. The thermoplastic revolution is here.
