Airliners Made of Lightweight Carbon Fibre Now Outnumber Aluminium Models

For over a century, commercial airliners were made from aluminium, comprising hundreds of thousands of sheets, frames, and rivets. However, with the introduction of Boeing's 787 Dreamliner in the late 2000s, the industry's building material underwent a significant change.

The new generation of airliners is primarily composed of carbon-fibre reinforced polymer (CFRP), a lightweight and durable material that offers several advantages over traditional aluminium. CFRP is built from ultra-strong filaments of carbon, thinner than human hair, which are laid up in a matrix of hardened resin.

This innovative material boasts a weight reduction of around 40% compared to aluminium for the same volume, making it an attractive choice for aircraft manufacturers. The Boeing 787, for instance, features a fuselage constructed from CFRP, with approximately 50% composite by weight, resulting in a 20% weight reduction over conventional aluminium construction.

CFRP also exhibits superior fatigue life, corrosion resistance, and durability compared to metal. Composites can withstand the repeated pressurize-depressurize cycles of airline flying much better than aluminium, which slowly weakens under these conditions.