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ADVANCED PLASTICS IN AEROSPACE: DESIGN & MATERIAL GUIDE FOR NEXT-GEN AIRCRAFT

Free White Paper For Aerospace Engineers, Project Managers, & Product Designers

Evaluating high-performance polymers for structural, interior, & fluid-handling components 

Aerospace teams are quickly replacing metal with choice advanced plastics as programs face relentless pressure to reduce weight, improve fuel efficiency, and meet stricter sustainability targets. However, many legacy designs are still constrained by traditional metals. This white paper explains how advanced thermoplastics and composites unlock lighter, more durable, and more manufacturable components without compromising safety or certification requirements. It also delves into: 

  • How material choices impact fuel burn, maintenance intervals, and total lifecycle cost.
  • Where high‑performance plastics can replace steel or aluminum in current platforms.
  • Key considerations for certifying polymer-based components in regulated aerospace environments.

Learn more in our most current white paper for aerospace teams.

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Inside This White Paper

The white paper walks through material selection, processing options, and performance trade‑offs so your team can specify the right plastics for future aerospace projects. These plastics handle harsh conditions, including high temperatures and repeated fluctuations without losing their integrity. Also, their chemical resistance ensures that they do not react with commonly used aircraft chemicals, making them great for a variety of aerospace applications.

Learn About Environmental Impact

  • How recyclability and circular-economy initiatives are reshaping material strategies for next‑generation aircraft.
  • Environmental and chemical resistance profiles relevant to aviation fuels, hydraulic fluids, cleaners, and de‑icing agents.

Understand Plastic Advantages

  • Advantages of advanced plastics vs. metals, including weight reduction, corrosion resistance, fatigue performance, and lifecycle economics.

  • Design and manufacturing considerations for high‑performance thermoplastics in machined, molded, and additive applications.

Advanced Plastic Types In Aerospace

The paper also highlights widely used  aerospace plastics and how to leverage specialized grades for demanding use cases. Specialized  high-performance materials commonly used include the following:

  • PEEK: Bearing, carbon‑filled, and EMI‑shielding formulations; suitability for high‑temperature, high‑load, and additive‑manufactured parts.
  • PEI (ULTEM): Common aerospace grades and where to deploy them for strength, flame retardance, and dimensional stability.
  • PPS: Linear high‑performance grades for chemically aggressive environments where tight tolerances and long‑term stability are critical.
The guide also touches on other advanced thermoplastics and custom-compounded options for niche aerospace applications.
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Built for Aerospace OEM Decision-Makers

This white paper is most suited for engineering, materials, and sourcing teams at aerospace OEMs and Tier 1/Tier 2 suppliers who are evaluating plastics for new platforms or redesigns. It is also useful for manufacturing engineers and program managers responsible for balancing performance, cost, and compliance.

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A Must-Read White Paper

Download the white paper to accelerate your next design review, support material justification with stakeholders, and de‑risk transitions from metal to advanced plastics in aerospace applications.