Thermoplastics represent an excellent material capable of a wide range of applications, from automotive to aerospace. Low scrap rate, excellent temperature resistance, recyclability, reduction in cycle time and part count, lower VOC emissions, lightweight with high-performance are some key benefits of thermoplastic prepreg. In light of these advantages, the replacement of metals and other materials seems natural.
The main Thermoplastic prepreg resins are Polyphenylene Sulphide (PPS), Polyetherimide (PEI), and Polyether Ether Ketone (PEEK). They are reinforced with common fibers such as glass and carbon fibers, and are then supplied in various forms. PPS holds over half of the share, followed by PEEK and PEI. The popularity of PPS can be ascribed to its excellent dimensional stability at elevated temperatures, its ability to be fabricated into complex geometries and high chemical inertness. Clips and cleats of fuselage frames are made mostly out of PPS.
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The Chemistry of Thermoplastics & Aircraft Parts
Carbon fibers are blessed with excellent mechanical properties such as lightweight, high strength-to-weight ratio, high tensile and compressive strength, low coefficient of thermal expansion, and high fatigue resistance. These qualities have found many applications in Aircraft; in airframe as well as interiors.
Ribs, spars, aileron structure, floor panels, and ice protection plates are few of many applications. The largest thermoplastic composite component in an aircraft in terms of part geometry is believed to be A380’s J nose, which is made of unidirectional prepreg, i.e. glass fibers impregnated with PPS resins.
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Looking into great detail the industry trends, growth drivers as well as factors constraining growth, Stratview Research prognosticates that market of Thermoplastic Prepeg shall grow at an impressive CAGR of 8.8% over the next five years to reach a market size of US$ 193million by 2023.
From the vantage point of the total prepeg market (thermoset and thermoplastic) which stood in excess of US$ 4 billion in 2017, thermoplastic prepreg accounted for a minuscule share. The fact highlights that Thermoplastic prepreg is at a nascent stage and has only begun to grow.
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