SABIC Features Relevant and Compliant Material Technologies that Meet Aircraft Weight-Out, Safety and Eco Challenges at Aircraft Interiors 2013

Oct. 2, 2013
It is exhibiting high-performance thermoplastic solutions that are helping aviation customers reduce weight and costs, enhance safety and sustainability.

SEATTLE, October 1, 2013 – Here at Aircraft Interiors EXPO, Booth 741, SABIC’s Innovative Plastics business is exhibiting high-performance thermoplastic solutions that are helping aviation customers reduce weight and costs, enhance safety and sustainability, and optimize the flying experience. And the need for the company’s relevant and compliant portfolio of resin, sheet, foam, fiber and composite technologies is growing, driven by increasing long-term demand for aircraft, an increase in passenger traffic, and a desire to reduce fuel costs. According to Boeing, between now and 2032, there will be a demand for 35,280 new airplanes, valued at $4.8 trillion. Of these new airplanes, 14,350 or 41 percent of the total new deliveries will replace older, less efficient airplanes. The remaining 20,930 airplanes will be for fleet growth, stimulating expansion in emerging markets and innovative airline business models.SABIC’s materials and technologies are playing a key role in answering these trends, helping aircraft OEMs conserve fuel and lower emissions; meet increasingly stringent flame-smoke-toxicity (FST) regulations; and enhance the comfort, aesthetics and distinctiveness of the cabin environment.

SABIC’s focus on customer needs for regulatory-compliant solutions for cabin interiors, seating, galleys and monuments, as well as hidden spaces inspires the company’s ongoing development of high performance materials and technologies. “SABIC continues to be a trusted partner for aerospace tiers and OEMs because of our demonstrated commitment to supporting the innovations that help our customers meet their most challenging demands,” Kim Choate, Marketing Director, Mass Transportation for SABIC’s Innovative Plastics business, said.

For a second consecutive year, SABIC is the sole sponsor of the VIP Lounge at the Aircraft Interiors EXPO, especially reserved for executive attendees from airlines, Tier suppliers and OEMs. “We are especially pleased to once again host the VIP Lounge, as it provides an excellent opportunity for  those who are shaping the future of commercial, private and defense aviation to meet,” Choate observed. 

Composites, Foam and Fibers Represent New Opportunities to Reduce Weight While Maintaining Strength

On average, an aircraft will burn about 0.03 kg (.06 lbs) of fuel per hour for each kilogram (2.2 lbs) carried on board. Given that the total commercial fleet flies approximately 57 million hours per year, cutting one kilogram per flight would save roughly 1,700 tons of fuel and 5,400 tons of carbon dioxide (CO2) per year2. SABIC’s high-performance, lightweight materials for aircraft interiors can make a significant contribution to fuel economy and emissions reduction and SABIC is displaying a diverse repertoire of solutions for aircraft interiors at its booth.

For example, a prototype tray table arm, made from SABIC’s 40 percent THERMOCOMPTM EC008PXQ compound – carbon-filled materials that are based on ULTEMTM polyetherimide (PEI) resin technology – provide exceptional stiffness and flow, which allows for the production of high-performance, thin-wall molded parts to replace airline grade die-cast aluminum in semi-structural components. Using the material enables a major weight savings and an increase in strength. Other potential applications include arm rests, foot rests, and galley applications such as coffee maker chassis. Building upon ULTEM resin’s proven capabilities for aircraft interiors, carbon-fiber-filled ULTEM resin complies with FAR 25.853 and the smoke density and heat release requirements of the Ohio State University (OSU) standard 65/65.

Also capitalizing on SABIC’s ULTEM resin technology, are examples of weight-saving technologies with potential application for non-structural components such as sidewalls, ceiling panels, overhead storage bins and cargo liners. ULTEM foam is a rigid, open-cell core material that is 10 to 20 times lighter than traditional plastic components. It is an excellent choice as a core material for composite applications requiring noise abatement, low moisture absorption, high thermal properties and compatibility with thermoset and metal laminates. ULTEM foam can be used as part of a composite system with a decorative film or surface layer such as phenolic prepreg or metal. Processes such as machining, vacuum bagging, compression molding and thermoforming can be utilized with ULTEM foam for potential system cost savings. Several different examples of thermoformable core and  sandwich samples, as well as compression molded foam samples will be showcased. 

Versatile ULTEM 9085 resin will be showcased in applications from Stratasys. Ductwork fabricated from ULTEM 9085 resin using Stratasys’ patented Fused Deposition ModelingTM demonstrates how low-volume parts with complex geometries can be made quickly and cost-effectively using additive manufacturing.

Aircraft insulation and seat fire blockers, developed by National Nonwovens, use ULTEM fiber to create an insulating, fireblocking layer used in seating, meeting FST and heat release requirements.  

ULTEM fibers are capable of being utilized in woven and non-woven applications. Examples of both glass- and carbon fiber-ULTEM woven fabrics will be on display at SABIC’s booth.

Delivering Top-flight Compliance, Aesthetics and Durability

In addition to superior performance vs. competitive materials, SABIC’s high-end thermoplastic products provide a host of other benefits for global aircraft designers ranging from long, useful life to regulatory compliance. Using these materials can help OEMs provide maximum comfort and appeal for passengers while ensuring a high level of safety and controlling costs.

SABIC’s booth will feature an important expansion of its industry leading LEXAN™ XHR sheet portfolio. The company’s new super low gloss LEXAN XHR 6005 sheet, shown in a thermoformed tray, brings velvet texture aesthetics after thermoforming for interior applications and the new LEXAN XHR A13 film adds robustness in multilayer laminate constructions used in decorative interior applications.

With its extremely low heat release, LEXAN XHR 6000 sheet series can deliver superior weight-out of up to 12 percent vs. traditional PVC/PMMA products for better fuel economy while fully complying with the Ohio State University (OSU) 65/65 standard, FST requirements (FAR25.853) of major airlines for seating, cockpit linings, window surrounds, door shrouds, and other interior components. It can be color-matched in sheet and resin form for color coordinated thermoformed and injection-molded parts. Available in more than 250 colors, LEXAN XHR sheet can reduce production costs, eliminate paint and withstand punishment in high-abuse applications. The product has improved texture retention and can be thermoformed at lower temperatures than traditional products, enabling the use of lower-cost tooling. All of these advantages, including low gloss finish, can help our customers lower their part cost and boost their productivity.

LEXAN XHRA13 film provides engineers and product developers a film grade with performance attributes of LEXAN XHR sheet that helps maintain and build robustness in multilayer lamination constructions that can be used for sidewall panels, ceiling, galleys, aisle facings, lavatory walls, premium seating, door linings and partitions. Available in gauges between 2-7mils, LEXAN XHR film complies with FAR 25.853 regulations and smoke density and heat release requirements.

A windowshade made from LEXAN XHR 5000 sheet is on display. Designed for multi-layer window shade systems requiring advanced FST properties and opacity, this industry-leading solution meets demanding safety requirements and also helps improve comfort in the cabin environment with a high-quality appearance and enhanced room-darkening properties.

“The dynamic nature of the aviation industry demands flexible high-end solutions that can address multiple challenges, including the ever-present need to control costs,” Choate said. “Our continued investment in innovative material technologies, together with our commitment to closely collaborate with aerospace customers, underscores SABIC’s leadership in developing space-age thermoplastic materials for next generation aircraft.”

For additional information on SABIC’s products for aircraft interiors, please go to www.sabic-ip.com. For technical product inquiries, please contact us at www.sabic-ip.com/prtechinquiry.

1 www.boeing.com/boeing/commercial/cmo/

2 www.enviro.aero