Lightweight aerospace programs demand materials that cut mass without compromising safety or lifecycle costs. For Tier 1 and 2 manufacturers designing the next generation of airframes, the challenge is clear: reduce weight while keeping maintenance and downtime under control. Success depends on selecting the right lightweight materials that deliver strength, reliability, and long-term performance in service.
The Role of Durability in Lightweight Aircraft Materials
When engineers choose lightweight materials, they’re aiming for more than just reducing the weight of a part. The right choice helps aerospace and military applications burn less fuel, extend service intervals, and minimize unscheduled repairs. In other words, durable materials lower costs and keep fleets flying longer between maintenance checks.
Durability also supports sustainability goals. Every kilogram of weight removed reduces fuel burn, directly cutting emissions. For more on how weight reduction drives efficiency, read about the role of lightweight components in fuel efficiency and emissions reduction in aerospace manufacturing.
Key Durability Factors in Lightweight Aircraft Materials
Strength to Weight Ratios
The most critical factor in a lightweight airplane component is its strength compared to its weight. Aerospace components and systems must handle aerodynamic forces, pressurization cycles, and landing loads while remaining as light as possible. High strength-to-weight ratios allow aircraft to perform reliably without excess bulk, improving efficiency and safety.
Environmental Durability
Aircraft face extreme environments every day: rapid temperature changes, corrosion from humidity and salt air, oxidation at high altitudes, and constant UV exposure. Lightweight aircraft materials must resist these stressors to avoid cracking, corrosion, or fatigue failure.
Durability of Common Lightweight Materials
Aluminum Alloys
Aluminum alloys remain workhorses of aerospace applications thanks to their excellent strength-to-weight ratios, versatility, and ease of repair. Advancements in alloy formulations and coatings have boosted corrosion resistance and fatigue performance, keeping aluminum critical for skins, fuselages, and frames in modern lightweight airplane design.
Titanium
Titanium is one of the most proven durable materials in aerospace. Known for its strength, heat resistance, and corrosion resistance, titanium is used in high-stress applications like engine mounts, landing gear, and structural fittings. While more costly than aluminum, its long service life often offsets the higher initial cost.
Stainless Steel
Though heavier, stainless steel offers exceptional resistance to fatigue and cracking in extreme conditions. The reliability of stainless steel under thermal and corrosive stress makes it a trusted choice for critical aerospace components. It is often specified where safety margins are non-negotiable, such as hydraulic systems or high-heat applications.
Future of Lightweight Materials
The aerospace industry is pushing for lightweight materials that are stronger and more durable. Emerging technologies are enabling lightweight airplane designs that reduce weight without compromising performance.
Nanomaterials
Carbon nanotubes and graphene-enhanced composites offer high strength-to-weight ratios, excellent heat resistance, and improved fatigue performance. While still in the research and development phase, nanotechnology in aerospace could redefine how structural and secondary components are built.
3D Printing
Additive manufacturing allows optimized geometries that reduce weight without compromising durability. Properly qualified 3D-printed metals support part consolidation, minimize waste, and enhance strength. The opportunity for 3D printing to advance lies in expanding design possibilities, improving material performance, and increasing production efficiently in airplane manufacturing. Discover more about the future of 3D printing.
Partnering with NMG Aerospace for Durable Lightweight Solutions
NMG Aerospace helps clients select the right durable materials and lightweight materials for every application. With deep expertise in alloys, composites, and advanced manufacturing processes, NMG supports everything from material selection and qualification testing to prototyping, production, and full lifecycle management. Our engineers work closely with clients to optimize designs and ensure components meet the strictest aerospace performance and safety standards.
Develop lighter, long-lasting components with NMG Aerospace. Contact us today to help our team understand how to best support your needs.
In the world of aerospace manufacturing, stakes are high. The industry is fast-moving and competitive, and the consequences of shoddy workmanship can be staggering—even deadly. An aerospace component that malfunctions during flight, takeoff, or landing can bring down the entire aircraft, with catastrophic results. Aircraft manufacturers are constantly striving for innovation while adhering to safety regulations, adapting to unexpected disruptions, and meeting tight budgets. It’s a balancing act, one that requires constant management and monitoring.
One common source of disruption in aerospace manufacturing is the global supply chain. As of July of 2025, the aerospace industry had a backlog of 17,000 new aircraft orders, a record high—and it may take over ten years to address it. Domestic and international shipping routes alike are vulnerable to a range of potential challenges, any of which can be highly disruptive without a proactive plan in place. This article will cover common supply chain challenges, strategies for accommodating these potential problems, and proactive ideas for staying ahead of the competition.
Common Challenges in Aerospace Supply Chain Management
The aerospace supply chain may encounter many of the same challenges as any other supply chain, including:
Geopolitical disturbances: Long, complex supply chains are especially vulnerable to things like regional disputes, fluctuating trade policies, and other geopolitical factors. The consequences can range from minor delays to significant pricing changes.
Natural and unpredictable disasters: Sometimes, supply chains are disrupted by truly unprecedented events that no one could have predicted or prevented. Recent examples include the COVID-19 pandemic, North American wildfires, and the Suez Canal blockage, all of which affected trade routes for months.
Some challenges, on the other hand, are somewhat unique to the aerospace industry:
Complex manufacturing needs: Some aerospace components are incredibly complex, requiring a level of customization that only experienced manufacturers with specialized capabilities can provide. When these manufacturers are in high demand, their customers can find themselves frustrated by how limited their options are.
Regulatory compliance: The aerospace industry is hardly the only sector that is subjected to countless regulatory requirements. However, there is a finite number of testing providers, with limited capacity. Achieving regulatory compliance is not optional, but it can take time.
Proactive Planning and Optimization Strategies for Aerospace Supply Chain Management
Aerospace supply chain disruptions can be unpredictable and unavoidable—but manufacturers are not without options. Proactive planning can give companies a tremendous advantage when disruptions do arise. Below are several aerospace supply chain management strategies to consider.
Supplier diversification: Companies with diverse supplier networks can be more nimble than their competitors. Building relationships with multiple suppliers gives companies the flexibility to make a seamless switch from one to another in the event of an issue, without having to go through the validation process every time.
Strong supplier relationships: In the event of a truly unprecedented disruption, a good relationship can be a lifesaver in terms of aerospace supply chain management. Companies can trust that their most trusted suppliers will prioritize their needs—but only if that relationship has been nurtured from the beginning. Investing time and effort into a close working relationship can pay major dividends when problems arise. Additionally, some aerospace companies choose to invest specifically in local or domestic manufacturers, to ensure a shorter, less vulnerable supply chain.
Reliable demand forecasting: No one has a crystal ball, but AI, supply and demand analysis, and other tools can provide predictive insight in uncertain situations. Identifying trends and preparing accordingly allows aerospace companies to act decisively, so they can make proactive plans for aerospace supply chain management and minimize the consequences of unexpected disruptions.
Continuous Improvement in Aerospace Supply Chain Management
In addition to proactive planning and optimization, aerospace companies can also embrace continuous improvement when seeking to plan for supply chain disruptions. Companies should always be looking for opportunities to do better: training team members, exploring new technologies, staying educated on regulatory changes, and more.
Customer feedback is an important part of continuous improvement. Even an offhand comment can be the key to making products and processes better, and finding ways to keep customers happy is key to maintaining customer loyalty, even when the industry is struggling with disruptions. An attitude of continuous improvement can unlock considerable advantages for aerospace companies seeking to minimize the consequences of supply chain disruptions.
Building Resilience in Aerospace Supply Chain Management
Navigating unexpected disruptions in the aerospace supply chain is an exercise in building resilience. Strong relationships, strategic technology investments, and long-established best practices are critical for companies striving to keep pace with the rapidly changing aerospace industry, even when disruptions threaten to derail their hard work.
NMG Aerospace is proud to have weathered decades of aerospace supply chain disruptions. With our established track record of high-quality manufacturing, efficient aerospace supply chain management, and excellent customer service, we have earned the trust of countless major players in the aerospace industry, who turn to us over and over when they need our help. From simple component manufacturing to full assembly production, testing, and beyond, NMG has the capacity, capabilities, and expertise you need to navigate the unexpected and keep your business on track.
To learn more about how NMG can help you, talk to us.
An aerospace assembly is a complete system that operates within an aircraft. For example, a landing gear assembly refers to the full suite of parts and components that comprise an aircraft landing system, in their assembled state. Of course, the quality and design of each individual component is important to the final performance of the assembly and the aircraft as a whole. But the aerospace assembly process also plays a role in aircraft performance.
Because so many aircraft systems fall under the definition of mission-critical, precision is of the utmost importance for aerospace assembly. Each component must fit and interact exactly as intended to ensure reliable functionality, even in intense circumstances. Continuing with the example of landing gear, an aircraft’s landing gear is its only system that makes direct contact with the runway during takeoff and landing and is responsible for bringing the plane to a halt in a timely manner, even if the runway is wet or conditions are otherwise less than ideal. Shoddy assembly of the landing gear could compromise its reliable performance and lead to a wide range of consequences, from an unbalanced landing to a catastrophic collision or belly flop. Precision during the assembly process goes a long way to ensuring that the landing gear and other critical systems perform exactly as designed.
One way to ensure the performance of an aerospace assembly is to test the assembly as a whole, as well as or instead of testing its many components. Quality and performance testing deliver valuable insight into the performance of a completed aerospace assembly in various environmental conditions, ranging from humidity and fluid exposure to vibration and altitude. Quality and performance testing can also assess how an aerospace assembly may respond to major shocks—or even a crash—by recreating forces in a controlled environment.
NMG Aerospace’s Assembly Capabilities
NMG Aerospace has long been a trusted provider of aerospace fabrication, assembly, and testing services for major aircraft manufacturers. We have considerable manufacturing assembly experience with aircraft landing gear and flight control actuators, but we’ve worked with a wide range of different aircraft assemblies. With our comprehensive on-site testing capabilities, we can assess the performance of every assembly ourselves, so you can trust that the final product will meet or exceed industry standards.
We have a proven track record of executing complex aerospace assembly and testing projects on deadline. With our decades of aircraft manufacturing experience and our full suite of aviation assembly technology, we can support all of your aerospace assembly needs.
Aerospace Assembly Component Manufacturing
The heart of NMG is aerospace manufacturing. Our extensive aerospace manufacturing capabilities include fabrication, precision machining, NADCAP welding, NADCAP chemical processing, and more.
We are proud to offer in-house manufacturing for high-performance components that are integrated into a wide range of critical aerospace assemblies. We have extensive experience with landing, pneumatic, safety, fluid, and seating systems and assemblies. From clean sheet design and material selection to finishing and aerospace assembly, we support every stage of the manufacturing process for aerospace components.
Aerospace Assembly
NMG has the on-site capability to put together full aerospace assemblies once component manufacturing is complete. For example, NMG may manufacture and assemble the packboards that house the working components of an evacuation slide, as well as some of the subcomponents inside the packboard. Those packboards are eventually installed on aircraft entry doors. We have invested in high-quality aviation assembly technology to ensure that each project meets our clients’ high expectations.
Aerospace Assembly Testing
As part of our commitment to providing service at every stage of the aerospace manufacturing process, NMG conducts on-site performance testing of aerospace assemblies and components. Our aerospace assembly testing capabilities are closely aligned with RTCA DO-160 and are flexible enough to combine multiple variables in a single testing scenario for custom assessments.
An excellent example of how NMG may support the development of an entire aerospace assembly is a thrust reverser actuator. We can manage the design process and machine the components ourselves, then assemble the full system. We can then verify that the thrust reverser actuators meet design specifications by testing the assembly for leaks, binding, and extend and retract times.
Precision and Quality
As an experienced aerospace manufacturing company, NMG understands the critical importance of precision and quality during fabrication, assembly, and design. Our aviation assembly technology is built for repeatability, and we perform multiple, rigorous quality checks throughout the process to ensure human eyes on every step. We proudly guarantee that every assembly from the NMG manufacturing floor will meet or exceed industry standards.
Why Choose NMG for Your Aerospace Assembly Needs
Years of Industry Experience
NMG has been a leader in the aerospace manufacturing industry for decades. Recent assembly projects, all of which are currently in use, include:
An actuator assembly for a military fighter jet
An actuator assembly for a military trainer
An actuator assembly for a Gulfstream business jet
Multiple evacuation slide assemblies for commercial aircraft
NADCAP and AS-9100 Certified
NMG’s rigorous quality practices and top-quality aerospace manufacturing services have earned us coveted NADCAP and AS-9100 certifications at our facilities in Stow, Ohio, and Tempe, Arizona. You can count on NMG to consistently adhere to stringent quality standards and exceed the expectations of the industry.
Customer-Focused Approach
If you need custom aerospace assembly services or expert support on an advanced assembly challenge, you can turn to NMG for tailored support. We have the expertise and the agility to develop custom solutions to your most pressing challenges and the aviation assembly technology to deliver an exceptional final product that will perform as intended.
Partner with NMG Aerospace
NMG Aerospace is proud to provide reliable aerospace manufacturing, assembly, and testing services for major aircraft manufacturers and other leaders in the aerospace industry. From aircraft landing gear and flight control actuators to other critical assemblies throughout the aircraft platform, NMG’s aerospace manufacturing services support reliable performance from takeoff to landing and beyond. We offer expert guidance from the earliest stages of assembly design through testing and validation of the final assembly.
Learn more about NMG’s fabrication, assembly, and design services. Talk to us.
The aerospace industry is experiencing rapid change as manufacturers explore and adopt new technologies. From artificial intelligence (AI) in aerospace to blockchain technology and beyond, these groundbreaking innovations are already having an impact on the way aircraft are designed and manufactured.
Artificial Intelligence (AI)
Artificial intelligence (AI) in aerospace has tremendous potential if leveraged thoughtfully and correctly. Manufacturing and maintenance represent just a small fraction of the possibilities represented by AI in aerospace.
Predictive Maintenance
One potential application of artificial intelligence in aerospace is predictive maintenance. AI can identify trends in maintenance schedules and detect small changes and inconsistencies in aerospace system performance. AI in aerospace systems can leverage that information to anticipate failures or issues before they happen or evolve into larger problems. By leveraging AI in aerospace to empower human workers to address maintenance concerns early, aerospace companies can reduce downtime and the incidence of more serious problems.
Quality Control
AI can be an excellent partner to human experts during the aerospace manufacturing quality control process. AI can detect inconsistencies that may be more challenging for a human quality assurance professional to spot, adding an additional layer of assurance to the quality control process.
Supply Chain Optimization
The global supply chain is vulnerable to a wide range of disruptions, from natural disasters to labor shortages. AI can rapidly assess multiple supply chain variables and determine the most efficient route for shipping and sourcing. As a result, aerospace companies can ensure timely delivery even when the global supply chain is experiencing disruptions.
Internet of Things (IoT)
The Internet of Things (IoT) is an umbrella term for physical objects with sensors connected via a wireless network. IoT and connected devices appear in a range of product categories, from home appliances to aerospace manufacturing equipment. Leveraging IoT in aviation and aircraft manufacturing has the potential to increase efficiency and enable confident decision-making.
Real-Time Monitoring
One way to leverage IoT in aviation is the strategic placement of sensors on aerospace manufacturing equipment. Sensors on IoT and connected devices can measure machine output and identify bottlenecks and other issues in real time. Technicians and supervisors can then investigate and find ways to make their aerospace manufacturing floor more efficient.
Asset Tracking
Some aerospace companies attach sensors directly to valuable assets for the purpose of tracking. The sensor delivers constant location data, making it all but impossible for the asset to go missing. This application of IoT in aviation can reduce loss and the headache of managing valuable assets in a fast-paced environment.
Data-Driven Decision Making
IoT and connected devices record more data than other types of equipment, supplying more information to managers and leaders who can leverage that input to make better decisions. With IoT in aviation, especially manufacturing, aerospace companies can optimize their systems and achieve greater efficiency.
Blockchain Technology
Blockchain technology is a new system for recording secure, verifiable, immutable records, especially sequential records, such as transactions or chains of custody. There may be significant potential for blockchain in aerospace.
Supply Chain Transparency
Blockchain technology removes any ambivalence surrounding the supply chain by creating an immutable record of any and all transactions, from purchases to transit. Leveraging blockchain in the aerospace supply chain ensures a consistent record between all parties.
Parts Traceability
Parts traceability is critical in aerospace. Aerospace parts often represent proprietary intellectual property and considerable investment in top-quality raw materials. Blockchain technology enables secure documentation of every stage of a component’s journey, from raw material procurement to quality assurance of the finished product, which reduces the risk of counterfeit parts and other issues.
Smart Contracts
One interesting application for blockchain in aerospace is smart contracts. A smart contract is a fully automated agreement that allows users to streamline transactions and enforce any regulatory compliance requirements with minimal human intervention. The result is more convenient records of agreements and contracts.
NMG’s Perspective on Emerging Technologies
With so many years of experience in aerospace manufacturing, NMG Aerospace has witnessed the adoption of countless new technologies and innovations. Our team is keeping close tabs on how blockchain technology, IoT technology, and AI in aerospace are adopted by airlines, manufacturers, and other leaders. We are cautiously optimistic about the potential represented by these new technologies for the future development of safer, smarter aerospace components, such as evacuation slide components, rub strips, and life raft systems.
Choose NMG Aerospace for Your Next Project
NMG Aerospace has proudly served as a trusted manufacturing partner for many major aerospace companies for over 60 years. We have witnessed and evolved alongside countless innovations and changes of the aerospace industry and have remained a steadfast source of support, service, and excellence for our valued customers.
You can count on NMG to help you manufacture excellent, high-performance aerospace components and navigate variables such as tight timelines and regulatory compliance with ease. From the earliest stages of aerospace component design to final performance testing, NMG has the expertise and experience you need to achieve your goals.
Excellent aircraft operations rely on durable materials that can withstand high heat and rigorous conditions. As the aerospace industry becomes more and more advanced, the demand for high-temperature materials continues to grow.
High-temperature alloys and materials are critical to the aerospace industry for several reasons:
Extreme Operating Environments
An airplane that takes off from a well-groomed runway for a scheduled domestic flight is not insulated against extreme operating conditions. Domestic fleets and rugged military aircraft alike may be subjected to high heat, severe cold, mechanical stresses and pressures, corrosion, radiation, and thermal shock while in operation.
With this in mind, there are two benefits to choosing high-temperature alloys for aerospace components. First, the materials can withstand high heat throughout the flight. Second, the materials can maintain their vital performance attributes even when subjected to high heat, which ensures reliable endurance against the rigors listed above.
Performance and Safety
High-temperature materials and aerospace alloys allow aerospace manufacturers to improve fuel efficiency and other parameters. For example, turbine efficiency can be increased by 5-6% by boosting the service temperature of the aircraft by 200°C. By leveraging high-temperature materials, aircraft can be operated at higher temperatures, and with the appropriate thermal barrier coatings and cooling systems, the aircraft can achieve better fuel efficiency.
High-temperature materials often have greater flexibility, radar absorption, and flutter suppression than their counterparts, along with high strength-to-weight ratios. This leads to greater stability throughout the aircraft.
Enabling Advanced Designs
The performance attributes of high-temperature materials and their compatibility with advanced manufacturing methods will likely translate to tremendous advancements in aerospace manufacturing and performance in the coming years. High-temperature materials may allow aerospace engineers to solve long-standing challenges and unlock new innovations in aerospace technology by raising the ceiling on operating temperatures.
High-Temperature Alloys and Other Materials for Aerospace
High-temperature materials range from alloys and polymers to composites featuring fibers and matrices. Examples of aerospace alloys and other high-temperature materials include:
Nickel Alloys
Nickel alloys are commonly used in aerospace applications, thanks to their excellent resistance to corrosion and temperature fatigue, caused by repeated exposure to heating and cooling cycles during flight. Nickel alloys are strong and easy to fabricate.
Titanium Alloys
Like nickel alloys, titanium alloys are highly resistant to corrosion and temperature fatigue. Additionally, titanium alloys are quite lightweight, a desirable attribute for manufacturers for whom lightweighting is a priority.
Copper Alloys
Copper alloys boast a few key performance attributes, including resistance to oxidation and creep, long low-cycle fatigue, and excellent strength at high temperatures. Some copper aerospace alloys are especially well suited to complex shaping, due to low thermal expansion.
Ceramic Matrix Composites (CMCs)
CMCs combine ceramic fibers with a ceramic matrix, resulting in a class of material that demonstrates excellent thermal stability, strength, and toughness. CMCs are a popular choice when lightweighting is a concern, since they are much lighter than metal alloys. CMCs are often used for jet engine components and heat shields.
Carbon-Carbon Composites
Carbon-carbon composites, made of carbon fibers embedded in a carbon matrix, are exceptionally well suited to endure the tremendous thermal load of reentry. These materials offer superb thermal conductivity and mechanical properties and are often used for heat shields.
Carbon-carbon composites offer inferior thermal shock and oxidation resistance to other high-temperature materials.
High-Temperature Polymers
Thanks to tremendous leaps in polymer composite research and high-temperature polymerization, high-temperature polymers with incredible performance attributes are becoming increasingly popular for aerospace applications. High-temperature polymers retain their thermal stability at high temperatures and are highly resistant to a wide range of chemicals. These materials demonstrate incredible tensile strength while weighing less than metal aerospace alloys. Additionally, the excellent thermal insulation properties of high-temperature polymers make them a popular choice for parts designed to protect sensitive aircraft systems and components from heat and electromagnetic interference.
Future Directions for High-Temperature Materials
The future of high-temperature materials is incredibly promising, with valuable research occurring in several key areas:
The next generation of aerospace alloys may outperform existing superalloys at ultrahigh temperatures. This has the potential to allow for tremendous innovation in turbine blade design.
Combining high-temperature materials with advanced manufacturing methods, such as additive manufacturing and powder metallurgy, may allow aerospace manufacturers to achieve more complex geometries.
The use of high-temperature polymers and ceramics is contributing to ongoing lightweighting efforts throughout the aerospace industry, which has a direct impact on the fuel efficiency and payload capacity of a given aircraft.
Partner with NMG Aerospace
High-temperature materials are bringing about significant innovation in the aerospace industry, allowing aircraft companies to explore new possibilities in flight. Tapping into the tremendous potential of these materials may require the support of an experienced aerospace manufacturer.
With decades of proven success in aerospace manufacturing and a strong record of compliance with Standards, Processing, and Air Agency certifications and approvals, NMG Aerospace has a long history of driving innovation across the industry.
We have earned the trust of countless aerospace companies, serving as their partner in innovative aerospace design and manufacturing. From expert fabrication and assembly to quality testing, NMG Aerospace can help you develop the next generation of your components and systems, so you can stay ahead of the competition.
To learn more about NMG Aerospace and our materials experience, contact us.
There are many ways to practice sustainability in aerospace. One popular and powerful strategy for improving sustainability is lightweighting, a central focus for aerospace research and development.
What Is Lightweighting?
Lightweighting refers to any design or manufacturing process that aims to reduce the weight of a part or component without compromising performance, durability, or reliability. Lightweighting may include optimizing the design of a component or part to eliminate needless bulk, opting for a lighter material, or a combination of changes.
The Science Behind Weight and Fuel Efficiency
The purpose of lightweighting is to reduce the overall weight of an aircraft or other vehicle, thereby decreasing the power needed for flight and improving fuel efficiency—a key sustainability metric.
According to an article from Quality Magazine, “eliminating one kilogram of material from an airplane reduces greenhouse gas emissions by saving 106 kilograms of jet fuel every year.” This can have dramatic impacts at scale for aerospace companies.
For example, consider a midsized airline with a fleet of 800 vehicles. Imagine the airline decides to replace a few components in each aircraft with a lightweight material alternative, resulting in an average weight reduction of 2.5 kilograms, or roughly 5.5 pounds, per aircraft. One year later, the airline will have reduced its annual fuel consumption by roughly 212,000 kilograms or 44,700 gallons. Assuming an average cost of $4 per gallon of jet fuel, the airline will save over $178,000 in a single year.
It’s worth noting that these calculations are based on incredibly modest numbers. At the 2022 International Materials Applications and Technology (IMAT) Conference, two researchers reported that strategic lightweighting initiatives can reduce the weight of the engine by up to 14% and the landing gear by up to 16%. Given that commercial aircraft engines weigh anywhere from 4,000 to upwards of 19,000 pounds, a 14% reduction in weight can have a tremendous impact on the fuel efficiency of the aircraft.
Why Lightweighting Matters in Modern Aircraft Design
The aerospace industry is one of many working to accommodate growing demands for sustainability and eco-friendly practices, such as lightweighting. This is occurring for several reasons:
For many consumers, sustainability is factored heavily into their purchasing decisions—and plane tickets are no exception. Sustainable practices, such as lightweight aircraft, are key to remaining competitive among passengers.
Materials That Are Changing the Aerospace Industry
The aerospace industry is experimenting with a wide range of materials to develop lightweight aircraft. This includes using established materials for new applications and exploring the use of new materials with exceptional properties. A few examples include:
Graphene
Carbon nanotubes
High-performance polymers
Advanced steel alloys, such as dual-phase steel
These materials offer the same reliability, durability, and performance as more traditional materials, at a much lower overall weight, supporting the goal of a lightweight aircraft. Strategically replacing heavier materials with any of these lightweight material alternatives reduces the weight of a given component and assembly without compromising the performance of the system.
The adoption of certain lightweight materials in aerospace manufacturing was made possible by incredible manufacturing innovations in recent years. These new manufacturing methods have allowed aircraft manufacturers to experiment with new materials and achieve greater efficiency overall. Manufacturing innovations enabling lightweight aircraft include:
3D Printing (also known as Additive Manufacturing): 3D printers create parts and components layer by layer. 3D printing and additive manufacturing are compatible with an incredibly wide range of materials, granting tremendous flexibility to the method. The potential applications for this new technology are virtually unlimited.
CNC Precision Machining: Unlike 3D printing, CNC precision machining creates parts by removing material from a solid piece of material. CNC machining allows for tremendous levels of detail and is a fantastic method for parts with tight tolerances.
Hydroforming: Hydroforming uses heated liquid media to shape metal pieces, often tubing, into precise shapes. Hydroforming generates less waste than other methods and is an excellent choice for irregular contours and complex parts.
Artificial intelligence (AI) and digital twins are also gaining traction in aerospace manufacturing. A digital twin is a digital replica of a real-world object, such as a part or aircraft. Manufacturers and engineers can simulate different environments and scenarios in a digital environment and observe the response and behavior of the digital twin, allowing them to predict the real-world performance of the part or assembly. This type of simulation testing is fast, efficient, and requires no prototypes, which can save time and resources, especially in the early stages of lightweight aircraft design.
Challenges in Lightweight Aerospace Component Production
While lightweighting offers tremendous benefits for aerospace companies, there are several challenges to consider when developing lightweight aircraft:
Compliance: Any given material for aerospace manufacturing needs to meet a lot of criteria before production begins. Lightweight aircraft materials must meet the requirements of the appropriate regulatory body and satisfy criteria for performance, durability, and safety.
Cost: While many lightweight materials are available at a comparable price point to their traditional counterparts, some are more expensive. Manufacturers must consider material costs against the benefits associated with a given material.
Manufacturing: Different materials behave differently in the manufacturing environment. Manufacturers must determine the appropriate manufacturing method, as well as compound formulation, when experimenting with lightweight materials.
Procurement: Depending on the state of the supply chain, certain lightweight materials may be more difficult to obtain. Ensuring a consistent supply can be a challenge, especially when working with a new material.
Manufacturers must be strategic and planful to overcome these challenges.
Partnering with NMG Aerospace for Lightweight Innovation
NMG Aerospace is proud to be part of the aerospace industry’s quest to make strides in the adoption of lightweight materials in aerospace manufacturing. With our company-wide commitment to continuous improvement, we are constantly striving to identify opportunities to optimize our manufacturing processes, which includes careful evaluation of opportunities for lightweighting. Our goal is for every new generation of components manufactured by NMG to support the industry goal of making the lightest possible aircraft, and we are proud to support our customers on that mission.
NMG can help you identify opportunities for lightweighting through design, material selection, and manufacturing method. To discuss your lightweighting goals with an expert, contact our team >
Why Sustainability Matters in Aerospace Manufacturing
The aerospace industry is one of many exploring ways to reduce its carbon footprint and adopt more sustainable practices. More and more consumers are naming sustainability among their core values and opting to patronize businesses that prioritize sustainable practices and invest resources into sustainability innovations. In other words, embracing sustainability may be critical to remaining competitive in the aerospace industry.
Many of these practices, such as sustainable materials, lightweighting, and waste reduction, happen at the manufacturing level. Aerospace manufacturing companies can contribute tremendously to the industry’s sustainability efforts by finding ways to leverage and implement sustainable practices.
Sustainable Materials Used in Aerospace Manufacturing
There are many ways to think about sustainability, from fuel consumption to recycling to waste management. One area rife with possibility for the aerospace industry is material selection. Strategic material selection can contribute to a wide range of sustainability goals, such as waste reduction, the use of more natural raw materials, and reduced fuel consumption by way of lightweighting.
Lightweight Materials
Many aircraft manufacturers are choosing lightweight materials as they pursue their sustainability goals. Choosing lightweight materials, or “lightweighting,” brings down the overall weight of the aircraft, which in turn reduces the amount of fuel required to fly the plane. Lightweighting can improve the fuel economy of the aircraft, with the compounding effect of dramatically reducing the fuel consumption of a single aircraft or an entire airline over time.
Bio-Based Composites
The aerospace industry has long relied on carbon fiber for aircraft manufacturing. Carbon fiber is strong, stiff, and durable, making it an excellent material for building airplanes. However, carbon fiber is usually made from fossil fuels, which may not align with some manufacturers’ sustainability goals.
Materials science experts have developed a new class of materials, called carbon composites, that may serve as an excellent alternative to carbon fiber. Carbon composites are strong and lightweight materials that offer many of the same performance attributes without using any fossil fuels. This new class of materials can be made from a wide range of biofibers and bioresins, like sugar cane and crop waste, water algae, bamboo, and others.
Thermoplastic Polymers
Thermoplastic polymers may be an attractive alternative to thermoset polymers and in fact already being used to create tooling and structural parts for fuselages and other components. Unlike thermoset polymers, thermoplastic polymers are 100% recyclable: This material can be melted and reformed over and over. While a broken or damaged thermoset polymer part must be discarded, a thermoplastic polymer part can be repaired by melting and reforming the damaged area—or recycled in its entirety to make a new part.
Additionally, thermoplastic polymers are lightweight materials compared to alternative options. Choosing thermoplastic polymer materials can be an excellent lightweighting strategy, which contributes to improved overall fuel economy. And because thermoplastic polymer parts can be connected by melting and welding the material together, there is no need for fasteners or other heavy components, which also supports lightweighting goals.
Even the manufacturing process for thermoplastic polymers is more sustainable. There is no need for an autoclave or cold storage, both of which consume considerable energy.
Recycled Materials
Many aircraft manufacturers are focusing their sustainability efforts on recyclable materials that can be returned to their raw state and remade. This includes aluminum, steel, titanium, and even carbon fiber. Choosing these recyclable materials cuts down on overall material consumption and waste production, two important metrics for sustainability.
NMG’s Commitment to Sustainable Manufacturing
NMG Aerospace is committed to exploring and adopting a wide range of sustainable manufacturing practices.
We make a conscious effort to cut down on material waste at our manufacturing facilities. We collect all machining debris, metal chips, and rejected parts, so we can reuse those materials, rather than letting them go to waste. We also place smaller stock orders to minimize leftover materials.
We know that even the smallest steps add up over time, which is why we have adopted a range of both basic and advanced practices for reducing energy consumption on site. For example, every single light bulb is programmed to turn off automatically, so we’re never wasting energy on illuminating an empty room.
Lastly, we have mastered the art of right-sized packaging, so we’re never using more material than necessary when shipping products to our customers. This practice reduces our material consumption and our overall carbon footprint.
Partner with NMG Aerospace
NMG Aerospace has years of experience with innovative design, strategic material selection, and optimized manufacturing practices for the aerospace industry. We can help you explore the possibility of a new design and choose the right material for your product. With our proven expertise in lean manufacturing and continuous improvement, you can trust us to deliver exceptional quality while finding ways to reduce waste and eliminate slowdowns.
Whether you’re just beginning to explore your sustainability options or ready to take your goals to the next level, talk to the team at NMG >
Ice accumulation poses a serious threat to aircraft safety and function. Ice can clog engine inlets and the vents on fuel tanks, compromising the mechanical performance of the aircraft. Ice formation on wings, tails, and propellers can alter the aerodynamics of the aircraft and reduce the pilot’s control over the flight. Ice buildup on the windshield can reduce visibility.
Simply put, unchecked ice accumulation introduces serious risk to any flight. Thankfully, most aircraft are outfitted with deicing systems to keep ice at bay.
What Is a Deicing System?
An aircraft deicing system is an assembly of components designed with the purpose of removing ice from an aircraft to alleviate any accumulation that might have a detrimental impact on flight and function.
There are a wide range of airplane deicing systems on the market, in three broad categories:
Inflatable Boots
Pneumatic boot systems are a classic example of an aircraft deicing system. The technology was first developed in the 1930s and has been standard technology since World War II. The boot is a long, inflatable rubber strip that is affixed along the aircraft’s wings, propeller, and tail, where ice most commonly accumulates. When the pilot inflates the boot, the outward force breaks any ice that has accumulated along the wing. The broken shards of ice are then simply blown away. This can be done repeatedly.
Timing is key with boot deicing systems. A boot can easily break through a thin layer of ice, but if the pilot waits until the buildup is too thick, a boot may not be sufficient.
Chemical Deicing Systems
A chemical deicing system uses glycol-based antifreeze solutions to address ice buildup. Electrical pumps force deicing fluid through tiny holes on the wings and other areas of the aircraft, and the fluid triggers a chemical breakdown of the accumulated ice. Chemical deicing systems can also be deployed preemptively to prevent ice buildup.
There are many different types of deicing fluid, differing in thickness and duration of efficacy. Fluids are chosen based on the speed of the aircraft and the severity of the anticipated ice buildup.
Thermal Deicing Systems
A thermal deicing system breaks down ice accumulation with heat. Some thermal deicing systems, called bleed air systems, route hot air from the engine through the wings and other surfaces to melt ice. Other systems, called electro-thermal systems, rely on embedded heating elements to heat wings and propellers.
Anti-icing vs. Deicing
There is an important distinction to be made between anti-icing and deicing systems. While deicing systems work to remove ice buildup, airplane anti-icing systems are engaged proactively to prevent ice accumulation from occurring at all. Aircraft anti-icing systems are often engaged continuously, whereas deicing systems are only used as needed.
Anti-icing is especially vital for windshields, wings, and engines. Ice buildup in these areas can compromise the safety and performance of the aircraft, which increases risk. Taking early steps to prevent ice accumulation is key to a safe flight.
There is significant overlap between aircraft anti-icing and deicing systems and technology. Some thermal systems keep the surface temperature of the wings above freezing at all times. Chemical systems can create a protective film or slick surface that prevents ice buildup.
Types & Applications of Deicing Valves Used in Aerospace
An airplane anti-icing or deicing system includes a number of different valves, each with a specific purpose related to directing and managing the flow of media. Examples include pressure regulation valves, distribution valves, relief valves, isolation valves, and solenoid valves.
Pressure Regulation Valves
A pressure regulation valve maintains constant pressure within the deicing system. The valve opens and closes to compensate for fluctuations that may occur in flight.
Distribution Valves
Distribution valves direct and control the flow of media through the deicing system. A distribution valve may divide a single stream of media into multiple streams to different zones or change the direction of flow.
Relief Valves
A relief valve is a safeguard against the dangers of excess pressure. When excess pressure builds up within a deicing system, the assembly can malfunction, leak, or even rupture. The relief valve is designed to quickly and safely release excess pressure, mitigating the risks of damage or malfunction.
Isolation Valves
For aerospace manufacturing applications, an isolation valve is used to stop the flow of media to certain zones of the deicing system.
Solenoid Valves
There are many applications for solenoid valves. In the context of a deicing system, solenoid valves control the flow of deicing fluid, air, and other media by opening and closing in response to electrical signals.
Partner with NMG Aerospace for Trustworthy Deicing System Solutions
NMG Aerospace is proud to be a leading expert in aircraft deicing systems, with significant experience in deicing system valves. Many leading aircraft manufacturers trust NMG to produce reliable, high-quality deicing system components and valves that perform as designed and ensure smooth operations at all times, even in extreme weather conditions.
From the early stages of aircraft design to final product testing before deployment, we offer high-level support and expertise during every phase of the aircraft deicing system manufacturing process. We can help you develop a new system from scratch, make improvements to an existing assembly, or simply find a faster way to manufacture your parts and components.
Ready to get started on your deicing systems project? Contact us >
3D printing and additive manufacturing are making waves all over the world as industry after industry begins to adopt and experiment with these new technologies. The use of 3D printing in the aerospace industry is already transforming the way components are designed and built, with more anticipated changes on the horizon as major aircraft manufacturers and beyond discover innovative applications for 3D printing in aviation.
Applications of 3D Printing in Aerospace
Additive manufacturing and 3D printing technology will play an important role in the future of aerospace manufacturing. One could argue that these technologies are still in their infancy, but many applications for 3D printing in aerospace can already be observed, from prototyping to strategic consolidations.
Rapid Prototyping
3D printing is much faster than some traditional aerospace manufacturing techniques, which is incredibly valuable at the prototyping stage of product development and aircraft design. Fast prototyping, empowered by 3D printing technology, allows aerospace companies to iterate on new ideas more efficiently, so they can put new innovations into practice sooner and stay ahead of the competition.
Weight Reduction
Leveraging 3D printing in the aerospace industry allows aircraft manufacturers to experiment with more weight reduction strategies. 3D printing is compatible with a wide range of lightweight materials, so aerospace companies can manufacture lighter components. This practice, often called “lightweighting,” translates to greater fuel efficiency and aircraft range, both of which are valuable in the aerospace industry.
Customizable Tooling
3D printing in aviation has tooling benefits as well. 3D printing allows aircraft manufacturers to build custom tooling faster and often at a lower cost, making highly customized parts – and greater innovation – more accessible.
Consolidation of Parts
Utilizing 3D printing in the aerospace industry allows for the consolidation of multiple components during the aircraft manufacturing process. By 3D printing multiple connected parts at once, aerospace companies can reduce the time and costs associated with complex assemblies.
Benefits of 3D Printing in Aerospace
The benefits of aerospace 3D printing range from waste reduction to greater innovation, leading to reduced costs and greater efficiency.
Reduced Material Waste
3D printing and other aerospace additive manufacturing techniques produce far less scrap material than some traditional methods. Integrating 3D printing into the aerospace industry allows aircraft manufacturers to cut down on waste and use materials more efficiently. This is especially valuable in the event of a material shortage and precious resources must be used judiciously.
Improved Design Flexibility
3D printing is an extremely flexible manufacturing process, offering nearly unlimited customization opportunities. 3D printing in aerospace gives aerospace manufacturers the flexibility to experiment with innovative designs of new and existing components, so they can continuously improve their aircraft and stay competitive in a fierce market.
Cost Savings
Aerospace companies can realize multiple avenues of cost savings when they opt for 3D printing. As previously mentioned, 3D printing uses material more efficiently and cuts down on scrap waste, reducing material costs. 3D printing also gives aircraft manufacturers the ability to build multiple components of an assembly at once, eliminating the costs associated with multiple assembly steps. Lastly, because 3D-printed parts can be lighter, airlines and other aircraft operators may realize savings on an operational level due to increased fuel efficiency.
Challenges and Future Developments
3D printing in aviation has tremendous potential for innovation and advancement. However, since this technology is still in its early stages, there are some current and future challenges to be aware of.
Material Limitation
For many aerospace components, material durability is a top consideration for performance and longevity. Unfortunately, certain materials simply are not compatible with 3D printing – at least not at this stage. The potential of 3D printing in aerospace is somewhat limited by the existing portfolio of materials that are both durable enough for aerospace applications and compatible with 3D printing.
Quality Control
3D printing is not immune to quality changes. Variability issues such as warping, porosity, and surface irregularities can occur, which is problematic for components with tight tolerances. Unfortunately, traditional quality control methods are not always sufficient for 3D-printed components. This is largely because the additive manufacturing process creates both material and geometry simultaneously, forcing manufacturers to essentially conduct two types of quality control at the same time. New quality control methods for 3D printing are in development, but aerospace companies must navigate this challenge creatively in the meantime.
Certifications
Industry standards and certifications are critical to ensuring uniformity and quality in any industry. Some regulatory bodies are more stringent than others about granting certifications. Because 3D printing is a newer addition to the aerospace manufacturing world, there are no existing certifications for this manufacturing method. Developing appropriate standards will take time, and some manufacturers may need to change their methods in order to earn these certifications once they are announced.
NMG Aerospace’s Commitment to Innovation
NMG has witnessed and supported decades of paradigm-shifting innovations in the aerospace industry. As a leading aerospace manufacturer, we are continuously investing time and resources into aerospace research and development. Mastering new innovations drives the future of aerospace manufacturing forward and supports our clients’ ambitious goals in this competitive industry.
From design support to U.S.-based manufacturing, NMG Aerospace is committed to supporting innovation at every stage of the aerospace component production process. To learn more about our services and capabilities, talk to a member of the NMG team.
A motor actuator valve, or motorized valve with an actuator, is a valve that opens and closes without human intervention thanks to a motorized power source. Motor actuator valves direct the flow of fluids and air in a wide range of applications, including aircraft and aerospace systems. This includes landing gear, engine control, fluid transfer, landing gear, and others.
A motorized valve with an actuator is considered an automated system, since the valve can be controlled by an input signal rather than a human operator.
Components of Motor Actuator Valves
There are three primary components of a motor actuator valve: the valve body, the actuator, and the actuator motor.
Valve Body
The valve body is the main component of a motor actuator valve. The valve body directs the flow of media within an aircraft system or aerospace fluid transfer assembly. The media differs depending on the application, but common media in aerospace contexts include water, hydraulic fluid, air, and combustible fuels. Motorized valve bodies are usually metal or plastic, depending on fluid exposures and other variables of the motor actuator valve’s service environment.
Actuator
The actuator converts power from the motor into mechanical motion, controlling the motorized valve.
Motor
The actuator motor powers the actuator. Usually, the motor and the actuator are connected by a gear or belt for power transfer.
Types & Applications of Actuator Valves Used in Aerospace
Motor actuators and motor actuator valves are among the most important components of any aircraft platform. Actuators trigger a wide range of essential aerospace functions, from simple valves to autopilot and landing gear operations. Motorized valves with actuators are extremely versatile, with multiple varieties found throughout many aircraft platforms.
Pneumatic Actuator Valve
A pneumatic actuator valve uses compressed air as a power source. Common applications for pneumatic actuator valves include high-cycle and rapid-cycle functions. Pneumatic actuation is an excellent choice for hazardous or explosive environments since there is no sparking. Pneumatic actuator valves are also well suited to high-temperature environments when paired with high-temperature seals.
Many pneumatic actuators use spring-return technology to move the valve into a “fail-safe” position if power or pneumatic pressure is lost for any reason, a desirable safety benefit for the aerospace industry.
Electric Actuator Valve
Electric actuator valves offer high flow precision for virtually any media used in aerospace applications, including nitrous oxide and combustible fuels. Electric actuators ensure extremely accurate positioning of valves and dampers, resulting in tight control of media flow. In addition to being highly dependable, electric actuator valves are smooth and quiet, which can be valuable in certain applications.
Many electric actuator valves offer a fail-in-place or “lock-up” feature. This means the valve freezes in place if the system loses power. Additionally, some electric actuator valves are fail-safe, like pneumatic actuator valves, though it should be noted that these are more expensive. Some companies may decide between fail-in-place and fail-safe electric actuators based on their budget and the application in question.
Hydraulic Actuator Valve
Hydraulic actuator valves are used to control the flow of water, air, fuel, hydraulic fluid, and other media that may be used in aerospace applications. Hydraulic actuator valves tend to be durable and powerful, making them a desirable option for high-force applications. Hydraulic actuator valves are also highly customizable, offering a wide range of configurations for different aerospace applications and aircraft systems.
Thermal Actuator Valve
Thermal actuator valves are controlled by a thermal actuator, which triggers mechanical motion, such as piston extension, in response to changes in temperature. Thermal actuator valves are highly precise and extremely accurate, a valuable asset in aerospace, where precision is often mission-critical. Thermal actuator valves provide constant modulation thanks to instant reactions to even minor changes in temperature, making them an excellent option for systems that require strict temperature control, such as fuel and oil temperature management and cabin environmental systems.
Choose NMG Aerospace for Your Actuator Valve Needs
NMG Aerospace has years of experience designing and manufacturing motor actuator valves for aerospace applications, ranging from simple tasks to complex operations. Many top aircraft manufacturers turn to NMG for expert guidance during the motor-operated actuator valve and actuator design process and trust us to supply quality motor actuator valves for mission-critical assemblies.
In addition to our extensive actuator expertise, NMG has spent years developing a rigorous in-house quality assurance process, with checks at regular intervals throughout design and manufacturing. Every member of our team undergoes intensive continuous improvement training, so we can work together to deliver high-quality products every time.
Manufacturing technology is growing in leaps and bounds in recent years – thanks to tremendous advancements in artificial intelligence (AI), new manufacturing techniques, and increased demand for sustainability. While not every trend has staying power, some manufacturing trends become best practices that drive aircraft industry growth for years to come.
Be the first to successfully integrate those fresh ideas into their own processes by staying informed on current trends in manufacturing and technological advancements. This results in better, more competitive products.
Continue reading for an overview of these manufacturing trends that will drive aircraft industry growth in 2025 and beyond.
Trend 1: Advancements in Additive Manufacturing (3-D Printing) in The Aerospace Industry
3D printing is one of the more newsworthy current trends in manufacturing. 3D printing and other additive manufacturing methods have become more sophisticated and widespread in recent years. 3D components are created layer by layer, using a wide range of materials. 3D printing and additive manufacturing allow for a great deal of complexity in terms of both shape and texture.
Because additive manufacturing, especially on an industrial scale, is fairly new technology, the long-term potential for the aerospace industry and the future of manufacturing remains to be seen. However, it’s safe to say that 3D printing and other new methods represent a world of possibility for aerospace component design and in the future of manufacturing.
Benefits of 3D Printing In Aircraft Manufacturing
It’s fast. 3D printing is more efficient than other manufacturing methods.
It’s cheap. Both the technology and the materials can be inexpensive, resulting in cost savings.
3D-printed parts are light. Weight reduction, or “lightweighting,” is incredibly valuable in the aerospace industry, where every ounce impacts the aircraft’s energy consumption.
The customization options are endless. 3D printers are compatible with a growing number of different materials, and product design is not hampered by the limitations of traditional manufacturing methods.
3D printing is eco-friendly. Many sustainable and recyclable materials are compatible with additive manufacturing technology, which produces far less scrap than other manufacturing methods.
Trend 2: An Increased Use of Sustainable Materials in Aerospace Manufacturing
Sustainable materials are a growing trend in aerospace manufacturing. This includes:
Thermoplastic polymers. In addition to being lightweight and durable, thermoplastic polymers are easy to recycle and repurpose. Additionally, the production process for thermoplastics consumes less energy than other materials. Thermoplastic polymers are commonly used to make everything from engine pylons and sensor plates to carbon partitions and luggage bins.
Bio-based composites. Traditionally, composites are made from fossil-sourced materials, such as petroleum. Many companies are experimenting with natural fibers, resins, and even wood to create more environmentally friendly composites that are just as light and strong as their predecessors.
Recycled materials. Aluminum, carbon fiber, and other materials can be recycled without any detrimental effects on their performance properties.
Sustainability goes hand in hand with regulatory compliance. Countless industries, from consumer products to aerospace, are changing their practices to comply with new and anticipated environmental regulations from government agencies and regulatory bodies all over the world, which is likely to have a major impact on the future of manufacturing. With more regions and industries embracing this manufacturing trend, adopting sustainable practices can be a smart, proactive step to ensure smoother compliance with future regulations.
Another trend in aerospace manufacturing is experimentation with more sustainable fuels, which is driving innovation in material selection for fuel assemblies.
Benefits of Sustainable Efforts in The Aerospace Industry
Choosing sustainable materials is just one option for companies looking to increase the sustainability of their business practices. Adopting other manufacturing trends related to sustainability has countless benefits, ranging from cost savings to brand image.
Sustainability is good for the environment. Companies can drastically reduce their carbon footprint and their environmental impact by adopting even just a few sustainable practices, such as choosing recycled materials or increasing energy efficiency at their facilities. This is critical for protecting and preserving wildlife, biodiversity, and delicate ecosystems all over the world.
Sustainability saves money. Recycled materials, waste reduction practices, energy-efficient manufacturing facilities, and fuel-efficient aircraft are often the less expensive alternatives, freeing up precious funds for other projects.
Sustainability is good PR. Consumers and companies alike are prioritizing sustainability when making purchasing decisions, a trend in aerospace manufacturing as well as other industries. Manufacturers that adhere to sustainable practices are more likely to earn these customers’ business.
Trend 3: How AI Is Used in Aerospace Manufacturing
Many people are aware of artificial intelligence (AI) as a tool for increasing efficiency and productivity in manufacturing environments. However, there are many applications for AI beyond productivity optimization. AI can predict failures and maintenance needs early, giving technicians the opportunity to correct small issues before they grow into big problems and reducing overall downtime. AI can also be used for quality control: AI systems can inspect finished components and assemblies and detect even the smallest defects.
The value of AI extends well beyond the manufacturing floor. AI can be a reliable tool for data analysis and demand forecasting, allowing manufacturers to make confident predictions about upcoming production volumes, customer needs, and other trends in aerospace manufacturing. This allows manufacturers to be good stewards of their time and resources and removes some of the guesswork from their planning processes as they strive to keep pace with aircraft industry growth.
The above is merely a sample of what AI is capable of. Scientists and business leaders are discovering new applications for AI every single day, and its countless uses will undoubtedly have a tremendous impact on aerospace manufacturing. From productivity and quality to forecasting and aerospace research and development, AI is likely to impact aircraft industry growth at every level and play a major role in shaping the future of manufacturing.
Trend 4: Digitalization and Smart Systems in Aerospace Manufacturing
Aerospace manufacturing is incorporating new digital tools and systems, such as the Internet of Things and simulation technology, into every step of the process. As these current trends in manufacturing become increasingly sophisticated, they open up new possibilities for aircraft industry growth, from increased efficiency to better equipment maintenance to waste reduction, and will have a tremendous impact on the future of manufacturing.
Smart Systems
“Smart system” is something of an umbrella term for systems that leverage a variety of tools, such as AI, Internet of Things (IoT), and machine learning, for the sake of optimization. Smart systems can monitor equipment, production, and other variables in search of opportunities to optimize for efficiency and improve quality output.
Internet of Things (IoT)
The Internet of Things (IoT) is a growing trend in aerospace manufacturing. IoT refers to the integration of sensors and intelligence into machines, from microwaves to manufacturing equipment. The general objective of IoT is to streamline communication between humans and machines, resulting in better coordination and greater efficiency.
In a manufacturing setting, sensors may be placed on every piece of equipment or system component on a given production line. These sensors gather and report data more quickly and more effectively than a human overseer, resulting in greater efficiency. For example, a sensor may detect a minor vibration or other anomaly indicating that a machine needs maintenance. Because technicians are notified early, they can find and fix the issue before it becomes a real problem. This type of predictive maintenance can reduce downtime, which is key in manufacturing.
Digital Twins & Simulations
A digital twin is a virtual copy of a physical object, with all the same traits and components. A digital twin allows product engineers and designers to test different iterations and improvements in a virtual environment without having to invest in physical prototypes at every stage of development. This can save time, reduce costs, and cut down on waste.
Prepare For Takeoff: Embrace the Future of Aerospace Manufacturing Today
With over 55 years of experience in aerospace manufacturing, NMG Aerospace has witnessed—and participated in—decades of technological advancement, manufacturing trends, and aircraft industry growth. We understand how to integrate new technologies with steadfast aerospace engineering and design principles and can help you leverage current trends in manufacturing in your own products.
Discover how to future-proof your aerospace manufacturing processes by integrating cutting-edge trends. Schedule a consultation with NMG Aerospace to stay ahead in 2025 and beyond.
Modern aerospace engineering demands components that perform reliably under extreme temperatures, pressure, and environmental stress. Identifying high-quality aerospace materials that can withstand these intense conditions is essential to ensuring safety, reducing failure risk, and extending component life.
Utilizing effective heat-resistant materials and fire-repellent materials is critical in high-temperature applications. Keep reading for more information about the different types of high-temperature materials, common aerospace applications for them, and the importance of choosing reliable aerospace components manufacturers.
Understanding High-Temperature Materials in Aerospace
The extreme thermal conditions faced by aerospace systems – from landing systems to jet engines – demand advanced aerospace materials that won’t degrade under intense heat. The use of fire-resistant, fire-repellent, and other high-temperature materials is critical to upholding high standards of safety in the aerospace industry and optimal component performance.
The right materials ensure that critical aerospace systems maintain their integrity and operate safely, minimizing risks associated with high-temperature environments. These high-performance materials are chosen by aerospace engineering companies for their balance of heat-resistant properties, durability, and efficiency. Integrating these high-temperature aerospace materials not only enhances performance but also extends the lifespan of components, reducing maintenance costs over time.
Types of High-Temperature Materials
Ready to learn about high-temperature materials used for aerospace components? Or wondering what materials are fireproof? First, let’s break down some definitions.
While all are related in terms of fire-resistant properties, fireproof materials do not burn or deteriorate when exposed to fire. There are also fire-resistant materials that withstand very high temperatures without melting or igniting, but may eventually be damaged by prolonged exposure. These are not to be confused with fire retardant materials, which slow or prevent the spread of fire. Aerospace engineering companies also look tofire-repellent materials that prevent ignition from occurring in the first place and other heat-resistant materials that endure high temperatures without significant degradation.
Learn more about the high-temperature materials commonly used:
Refractory Metals
Refractory metals — including tungsten, molybdenum, tantalum, and niobium — are known for their exceptional melting points, often exceeding 2,000°C. These metals are heat-resistant and maintain stability, making them ideal for aerospace environments where components must withstand long-term exposure to extreme temperatures. Their heat tolerance and strength under thermal stress make them valuable materials for aircraft machining and component manufacturing.
Ceramics
Ceramics are lightweight, non-metallic, and can endure extreme temperatures without melting or warping, categorizing them as heat-resistant materials. With resistance to heat, wear, and corrosion, ceramic materials are commonly used by aerospace engineering companies. Ceramic materials can be further enhanced as composite aerospace solutions, like ceramic matrix composites (CMCs), which improve component strength and fracture resistance.
Superalloys
Commonly made from nickel, cobalt, and iron, superalloys are engineered to withstand high temperatures while maintaining strength and oxidation resistance. Superalloys are commonly used in turbine blades and other critical engine parts, where they contribute to both safety and operational efficiency. Though not a fireproof material, they are considered fire retardant due to their ability to resist heat and prevent the spread of flames in high-heat environments.
Carbon-Based Materials
Carbon-based materials, including graphite and carbon composites, offer both lightweight properties and high heat tolerance, which are ideal for a wide range of aerospace applications. They effectively dissipate heat and resist thermal shock, allowing them to endure sudden temperature changes without cracking or deforming. For example, carbon-based composites are frequently used in aircraft landing systems like brakes, providing robust fireproof material solutions that withstand extreme conditions without igniting.
Applications in Modern Aerospace
The use of high-temperature aerospace materials is essential across multiple critical systems. Here are a few of the main areas where these materials play a pivotal role:
Jet Engine Components
Aerospace components manufacturers rely on high-strength stainless steels and nickel-based superalloys for jet engine components, like fuel control values and hydraulic actuator valves. Superalloys and ceramic matrix composites are also commonly used for turbine blades and combustion chambers. These materials provide the durability required to perform reliably under the extreme conditions inside jet engines, where temperatures and pressures are consistently high.
Braking Systems
Aircraft braking systems require materials that can resist intense heat and friction. Fireproof materials like carbon-based composites provide high thermal stability and wear resistance, making them ideal for aerospace brakes, where consistent performance under high stress is essential.
Insulation Barriers
Insulation barriers are designed to protect sensitive equipment from excessive heat, particularly in aerospace applications. Made from advanced materials like ceramics and carbon-based fire retardants, these barriers offer exceptional thermal resistance and fire-retardant properties.
Precision Machined Components
Precision-machined components are essential in aerospace for parts that must resist extreme heat. Using heat-resistant and fire-retardant materials such as advanced alloys and fire-resistant metals, these components – including landing gear, aircraft evacuation and actuation components – are precision machined to maintain integrity under high temperatures. Precision machining also ensures dimensional accuracy and adherence to stringent industry standards.
Partner with NMG for High-Quality Aerospace Solutions
Working with a reliable aerospace components manufacturer is crucial to maintaining safety, efficiency, and durability in aerospace applications. With extensive experience in aerospace materials, precision machining, and aircraft component manufacturing, NMG Aerospace provides high-performance solutions that exceed the demanding requirements of aerospace engineering companies.
Contact us today to learn how NMG Aerospace can elevate your projects with high-quality aerospace materials and solutions.
