Airbus and Boeing Ditch Traditional Autoclaves in Quest for Faster Aircraft Production

Two major aerospace manufacturers, Airbus and Boeing, are racing to develop new composite manufacturing methods that bypass traditional autoclaves. These large pressurized ovens cure resin-impregnated carbon fiber layups under precise heat and pressure, but they're slow, energy-intensive, and capacity-limited.

The current process can't scale to meet the production rates required for a successor to the A320 and 737 families. For example, the Boeing 787 and Airbus A350 require hours inside massive autoclaves, followed by inspection and finishing cycles. The capital cost of these facilities is substantial, and each unit represents a fixed throughput ceiling.

Airbus and Boeing are exploring several alternatives to the autoclave, including thermoplastic composites, resin transfer molding (RTM), and out-of-autoclave prepreg systems. Thermoplastics soften when heated and harden when cooled, allowing parts to be welded rather than fastened or bonded.

Automation of layup, inspection, and joining processes is equally important for increasing production rates. Automated fiber placement machines already lay composite tape at high speeds, but downstream steps remain labor-intensive. The goal is a fuselage that moves from station to station on a moving line, with each station adding a section or completing a joint in minutes rather than hours.

Both manufacturers face significant industrial and supply chain risks as they transition away from traditional autoclaves. Investment decisions at suppliers like Toray, Hexcel, and Solvay will shape which technologies reach industrial maturity first.