Airbus and Boeing Ditch Autoclaves for Next-Gen Composite Manufacturing

Airbus and Boeing are racing to develop new composite manufacturing methods that don't rely on traditional autoclaves, which are slow and energy-intensive. The companies face a common problem: scaling up production of carbon fiber airframes for their next-generation single-aisle airliners.

The autoclave has been the standard method for producing composite structures for decades, but it's not suitable for the high production rates needed for narrowbody aircraft. For instance, Airbus' A320 successor is expected to enter service in the second half of the 2030s and will require a significant increase in production capacity.

Several technologies are being explored as alternatives to the autoclave, including thermoplastic composites, resin transfer molding (RTM), and out-of-autoclave prepreg systems. Thermoplastics can be welded rather than fastened or bonded, potentially eliminating thousands of rivets from a fuselage.

Airbus is working on developing thermoplastic technology through its Wing of Tomorrow program and partnerships with suppliers experienced in the material class. Boeing has also explored out-of-autoclave prepreg systems, demonstrating related concepts through its Boeing Research and Technology work and earlier programs conducted with NASA.

The shift away from the autoclave represents one of the most consequential manufacturing transitions since the introduction of composite primary structure itself. The decisions taken in the next few years will define airliner manufacturing for the following three decades.