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IMPLEMENTING ADVANCED PLASTIC MATERIALS IN FUTURE AEROSPACE PROJECTS

Free White Paper For Aerospace Engineers, Project Managers, & Product Designers
The aerospace industry is undergoing a transformation driven by the need for lighter, stronger, and more fuel-efficient aircraft. At the core of this shift is the increasing use of advanced plastics and composite materials. Their selection for aircraft plays a crucial role in achieving performance and sustainability goals. Advanced plastic materials and their manufacturing are at the forefront of this transformation, offering significant advantages. This white paper explores the material selection, manufacturing processes, and performance benefits of these advanced polymers in the aerospace industry. 

Learn more in our most current white paper.

advanced aerospace plastics

Advantages of Advanced Plastics For Aerospace Applications

Advanced plastic materials offer several advantages to aerospace applications over traditional materials, such as steel or aluminum. They are lighter, more resistant to corrosion and fatigue, and often lower lifecycle costs. These plastics handle harsh conditions, including high temperatures and repeated fluctuations without losing their integrity. Their chemical resistance ensures that they do not react with commonly used aircraft chemicals, making them ideal for a variety of aerospace applications.

 

 

Recyclability & Circular Economical Properties

 

Some ambitious green-minded initiatives have instituted many regulatory frameworks that are significantly reshaping material selection priorities. These initiatives insist that aircraft materials not only meet strict performance and safety standards but also support end-of-life recyclability and reduce future environmental impact. Many different types of plastic can meet this growing demand for recyclability. 

Weight Reductions & Component Consolidation

 

As fuel costs, sustainability goals, and performance demands intensify, traditional materials are reaching their limits. Advanced composites offer a compelling alternative, enabling some industries to achieve significant weight reductions (up to 20–30% over metallic structures) not only from the material but also from the consolidation that systems experience from advancing in these areas.  

 

 

 

Advanced Plastic Types In Aerospace

High-performance polymers such as PEEK, PEI, and PPS offer unique advantages in aerospace applications. Most thermoplastics such as these can be further enhanced to improve properties, allowing for highly customized solutions tailored to niche applications. The material listed here are just a few examples, bu they are among the most used in aerospace components.

PEEK

PEEK continues to evolve with specialized formulations designed for specific aerospace applications. This includes bearing-grade variants and carbon-filled compositions that provide enhanced conductivity for electromagnetic interference (EMI) shielding applications and additive manufacturing grades. These maintain the material's inherent flame resistance and chemical compatibility while also enabling complex geometric freedom through 3D printing technologies.

A round gray flanged PEEK plastic component with multiple holes next to a beige PEEK rectangular block with threaded holes, both on a plain background.

PEI (ULTEM™)

PEI formulations, especially those marketed under the ULTEM™ brand, have expanded to include specialized grades such as ULTEM™ 4100 and ULTEM™ 5000 that provide enhanced chemical resistance and improved processing characteristics.

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PPS (Polyphenylene Sulfide)

PPS has seen significant development in linear polymer variants that provide augmented mechanical properties and improved chemical resistance compared to traditional chemically branched formulations. These materials offer exceptional performance in chemically aggressive environments while maintaining dimensional precision.

 

 

A cylindrical, copper-brown PPS plastic insulator component with several grooves, holes, and ridges, photographed on a white background.

A Must-Read White Paper

Want to know more about how plastics are revolutionizing aerospace?