As the aerospace industry readies itself for the development of next generation single-aisle commercial aircraft and the burgeoning market for Advanced Air Mobility (AAM) electric aircraft, Hexcel is positioning itself to meet the growing demand for high-rate composite manufacturing. At the recent Carbon Fiber 2024 Conference in Charleston, SC, Imad Atallah, Vice President of Product Management - Fibers, Reinforcements, and Matrix at Hexcel, outlined the company's multi-faceted approach to supporting this critical industry need.

"The entitlement of composites is not guaranteed on the next generation aircraft," Atallah warned the audience. "Cost, maintenance, and sustainability are going to be key factors that will influence how much composite content makes it onto the next single-aisle plane." To address these challenges, Hexcel is pursuing a diverse range of material systems, processing methods, and technologies.

"Unlike what we've seen on the A350 and 787, it's not going to be one material that solves all the problems," Atallah explained. "There's going to be a variety of solutions that we need to optimize for different part sizes, complexities, and automation possibilities."

Hexcel's vertical integration strategy plays a key role in its ability to provide tailored composite solutions. "Our ability to manufacture carbon fiber, prepreg resin systems, and honeycomb in-house allows us to closely integrate these components and develop high-performing materials optimized for high-rate production," Atallah explained.

The company is also expert at a range of processing technologies to enable high-rate manufacturing, including compression molding, out-of-autoclave methods, and accelerated autoclave curing. "We're not just focused on faster cure resins," Atallah noted. "We're also working with processing firms, equipment manufacturers, and other partners to develop truly innovative solutions."

Looking ahead, Atallah emphasized Hexcel's commitment to providing the composite materials and expertise to help its customers achieve their high-rate manufacturing goals. He states, "When it comes to aerospace, we're dedicated to earning the entitlement of composites on the next generation of single-aisle aircraft and AAM vehicles."

As the aerospace industry accelerates towards the future, Hexcel is positioning itself as a strategic partner in the quest for high-rate composite manufacturing. With its diverse material portfolio, processing expertise, and collaborative approach, the company is poised to play a pivotal role in shaping the next chapter of aerospace innovation.