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:
- Sustainability is becoming increasingly important to the regulatory environment for airplanes and aerospace. For example, the National Air Transportation Association (NATA) has introduced its Sustainability Standard for Aviation Businesses, a free, voluntary standard designed to encourage sustainability throughout the industry. Another example is the International Civil Aviation Organization (ICAO).
- 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.
Manufacturing Innovations Enabling Lightweight Aircraft
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 >
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