Aviation Industry Shifts from Aluminum to Carbon Fiber

For nearly a century, commercial aircraft were built from aluminum: thousands of panels, frames, and rivets attached to a metal tube. However, with the introduction of Boeing's 787 Dreamliner, the industry's fundamental building material changed.

The latest generation of commercial aircraft is essentially made of woven plastic and adhesive: carbon fiber reinforced polymers (CFRP).

This sounds like a step backward, but it isn't. According to data, CFRP is approximately 40% lighter than aluminum for the same volume. It also resists fatigue and corrosion five to ten times better than metal.

Boeing's 787 Dreamliner features around 50% composite material by weight, representing a 20% reduction in weight compared to traditional aluminum construction. The aircraft's fuselage is built like a single barrel, with fewer joints and less aerodynamic resistance.

Airbus responded to the 787 with the A350 XWB, a wide-body aircraft featuring a completely new composite design.

While materials composites are not perfect, their manufacturing process is costly, and they can be difficult to inspect for internal damage, the benefits far outweigh the drawbacks. Composite structures offer greater strength-to-weight ratios, allowing airlines to fly farther with less fuel.