Thermoplastic composites: rethinking aerostructures for more sustainable aviation
Reducing fuel consumption, improving aircraft performance, increasing production rates and limiting environmental impact: the aerospace industry must address several major challenges simultaneously.
To support this transformation, Daher has been investing for more than a decade in the development and industrialization of thermoplastic composites, a technology set to play a key role in future aerospace programs.
Lighter, repairable, weldable and recyclable, thermoplastic composites open up new possibilities for designing higher-performance aerostructures while reducing resource consumption and associated emissions. Their compatibility with highly automated manufacturing processes also makes them a major lever for supporting production ramp-ups across the aerospace industry.
At the heart of the Shap’in techcenter, Daher develops, tests and industrializes these technologies in collaboration with customers, industrial partners, start-ups and academic stakeholders. The objective is clear: transform composite innovation into practical solutions for future aircraft and more efficient, lower-carbon aviation.
Why are thermoplastics a game changer?
Unlike traditional materials or thermoset composites, thermoplastic composites offer several major advantages for aerospace applications:
- Lighter structures that help reduce fuel consumption;
- Repairable and recyclable materials;
- Greater manufacturing automation;
- Shorter production cycles;
- Solutions adapted to production ramp-up requirements;
- High mechanical performance in demanding environments.
These characteristics improve industrial performance, enhance program competitiveness and reduce environmental impact at the same time.
Shap’in: accelerating composite innovation
Located near Nantes, the Shap’in techcenter is dedicated to the industrialization of advanced composites and the development of next-generation aerostructures.
Its activities focus on:
- Next-generation thermoplastic materials;
- Automated production processes;
- Composite welding technologies;
- Lightweight structural design;
- Material recyclability and circularity.
Through a collaborative innovation ecosystem bringing together industrial companies, aircraft manufacturers, SMEs, start-ups and research organizations, Shap’in accelerates the transition from research to industrial deployment.
Innovation already in action
Thermoplastic composites are no longer confined to the laboratory. Daher is progressively integrating them into demonstrators and applications designed for future aerospace programmes.
Flagship achievements include the development of a highly loaded thermoplastic wing rib, which was recognised at the JEC Composites Innovation Awards, as well as a full-scale horizontal stabiliser demonstrator developed as part of the TRAMPOLINE 2 project, France’s leading research programme dedicated to thermoplastic composites. Conducted within the framework of CORAC and led by Daher, the project explores the potential of induction welding as an alternative to traditional riveting, with the aim of reducing structural weight while simplifying assembly processes.
Daher is also involved in the CARAC TP project, carried out in partnership with several academic laboratories, to gain a deeper understanding of and better characterise the behaviour of thermoplastic composites in the most demanding aerospace environments. This work helps accelerate their certification and integration into future aircraft programmes.
These advances extend beyond technology demonstrators. Daher has notably developed TBM rudder pedals made from reclaimed thermoplastic composite material sourced from production offcuts. This achievement provides a tangible illustration of the potential of thermoplastic materials to combine lightweight design, industrial performance and circular economy principles.
Toward a more circular use of materials
Beyond developing new aerostructures, Daher is also working to maximize the value of thermoplastic materials throughout their life cycle.
At Shap’in, production offcuts from composite manufacturing are collected and transformed into new raw materials for technical parts and additive manufacturing applications. Today, all pure PPS carbon composite offcuts from certain manufacturing processes are reintegrated into a dedicated recovery and reuse stream.
This approach helps reduce waste, optimize resource use and strengthen material circularity within the aerospace industry.
> Watch the video : Upcycling of thermoplastic production waste
A key technology for future aerospace programs
Lightweight structures, waste reduction, industrialized processes and material recyclability make thermoplastic composites one of the most promising technologies for supporting the future evolution of aerospace.
Building on the work carried out at Shap’in, Daher is preparing the technologies that will contribute to future aircraft, with the ambition of combining performance, industrial competitiveness and reduced environmental impact.
