With the leading of Boeing 787 Dreamliner and Airbus A350 XWB, commercial airlines are gradually making more use of carbon fiber composites to manufacture aircraft fuselage. Because carbon fiber is stronger than steel and lighter than aluminum, it can be molded into almost any shape. No wonder aerospace engineers use carbon fiber composite structural materials to design their dream aircraft. Coupled with reduced fuel costs, improved aerodynamics and fewer part requirements, it is not difficult to see that carbon fiber is ready to become the structural material of aircraft in the future.

Carbon fiber improves fuel efficiency

As we all know, in the aviation industry, the lighter the aircraft, the lower the operating cost. The lower weight improves fuel efficiency, which greatly reduces the overall operating cost of the aircraft. Because the weight of carbon fiber composites is very strong, aircraft manufacturers are leaning in this direction. Compared with traditional aluminum aircraft, the weight of aircraft made of carbon fiber composites can be reduced by 20%. It is estimated that each kilogram of weight reduction will save about $1 million in the whole life cycle of the aircraft. A lot of money has been saved!

Carbon fiber improves aerodynamic performance

In addition to reducing weight, another important factor in aircraft fuel efficiency is aerodynamics. The more fashionable the design, the higher the fuel efficiency of the aircraft. Because the manufacturing process of carbon fiber composites can produce very smooth but complex geometry, aircraft designers can more easily optimize the aerodynamic performance of carbon fiber aircraft. In addition, the stiffness of carbon fiber also helps to use the swept back wing design in commercial aircraft, reducing fuel consumption by an additional 5% by reducing aerodynamic drag.

Carbon fiber reduces the number of parts

Another area where the use of carbon fiber in aircraft manufacturing can help reduce costs is the number of parts required for aircraft manufacturing. For example, the Airbus A380 typically consists of about 6 million parts. However, since carbon fiber composite parts are molded, each mold can be designed to combine several different parts into one mold, significantly reducing the number of parts required to build a plane. Since fewer parts are required to build an aircraft, it also requires less manufacturing time. In addition, due to the lighter weight of carbon fiber components, less personnel are required for operation and assembly. All these factors together have greatly saved the cost of aircraft manufacturing.

Aircraft design using carbon fiber in the future

In terms of controlling aerodynamic efficiency and saving fuel, using carbon fiber composites instead of traditional metals to manufacture aircraft can provide aircraft designers with greater flexibility. This flexibility also gives people the opportunity to change the traditional aircraft design. Future commercial aircraft may include a design that combines fuselage and wings, similar to some military aircraft today. This type of design greatly improves the lift / drop ratio of the aircraft, makes the aircraft more aerodynamic effective, and still reduces the weight. A new Airbus concept aircraft has introduced an aircraft with a fatter, curved fuselage designed to improve airflow and provide more cabin space. Longer, thinner wings will reduce drag and improve fuel efficiency. The U-tail acts as a shield to reduce engine noise. Carbon fiber can even conceive all these concepts.

Although carbon fiber composites have been used in aircraft manufacturing since the 1970s, with the improvement of manufacturing technology, it has become more and more common to find new methods to use this incredible resource in the design and manufacturing of commercial aircraft. Due to its light weight, amazing strength and smooth surface, carbon fiber composite is an ideal material for manufacturing many aircraft parts. The use of carbon fiber in aircraft airframe can make them more fuel-efficient, more aerodynamic, and can make aircraft with fewer and lighter parts. All these factors together reduce manufacturing and operating costs. No wonder today's concept aircraft use more carbon fiber composites. Obviously, carbon fiber will become the main material for building aircraft body in the future.