Top 5 Ways Aircraft Interior Plastics Help You

Since 1970, plastic has played a significant role in the aerospace sector. They plummet the aircraft's weight and increase its fuel efficiency. When it comes to military aircraft, they assist in extending flight range and avoiding radar detection. Plastic is used for propulsion and navigational tasks, as well as structural elements and interior components. Make sure to look for the best plastic for aircraft interiors. Plastic offers a plethora of benefits that make it an excellent choice for the aircraft industry: 

• Chemical-resistance

• Corrosion-resistance

• Lightweight

• Durable

• Impact-resistance 

By 2025, the aerospace plastics industry is expected to reach $75 million. This increase in demand can be ascribed to the fact that they help the production process while also improving interiors. So, it is a prudent choice to look for Check out these five major advantages to guarantee you're up to date on the worth of plastics.

 

Top Ways Aircraft Interior Plastics Help Manufacturers

 

1. Enhanced Versatility

Plastics can be utilized in a range of aircraft interior applications, like as seats, trimmings, in-flight entertainment systems, windows, overhead bins, and more. Manufacturers don't need to use numerous substrates across multiple applications in their production process because of the adaptability. You can also look for airplane composite materials online. 

 

2. Better Design Opportunities

 

Plastics enable design innovation for aircraft interior components because they are a cost-effective, multifaceted option. Plastics may be easily molded to produce pieces that are not only functional but also pleasant to the eye. Plastics have been put to the test in recent years to produce aircraft with touchless toilets, increased storage capacity, and removable tray tables.

 

Plastics also provide more customizing options. Designers have more freedom to experiment with color palettes, textures, and patterns to produce appealing aesthetics without sacrificing utility.

 

3. Increased Durability: Plastics are extremely long-lasting. Plastics are resistant to scratches and nicks caused by foot traffic while in use, extending the life of the aircraft interior. Plastics can also withstand high temperatures and are resistant to harsh chemicals, making them an ideal material for aircraft that operate in a variety of environments. Make sure to look for aircraft interior components.

 

4. Increased Fuel Economy: Plastics improve an aircraft's fuel efficiency. Some plastic parts are up to ten times lighter than their metal counterparts. Over the life of an aeroplane, each pound of weight avoided can save up to $1,000 in fuel expenses.

 

Even though they are lightweight, aircraft interior polymers maintain their structural integrity. Plastics are long-lasting and work well under rigorous use, even with strong foot traffic and frequent cleaning.

 

5. Passenger comfort: Plastics in aircraft interiors allow producers to match passenger requests. Reduced weight in the aircraft's body allows for additional cargo capacity in overhead bins and other storage locations for passengers. Plastics also allow for seating and space advancements due to their malleable nature. For a more comfortable flight experience, future plastic applications could include double-decker seating or walls between seats.

 

Manufacturers gain from aircraft interior plastics in a variety of ways. Using the correct adhesive can help you incorporate more plastics into your production line, allowing you to reap the benefits.

 

Conclusion

Plastics that are heat-resistant and noncorrosive can be manufactured to substitute metal fasteners and screws. Existing machined parts do not require any changes in their overall design, allowing for straightforward replacement of OEM components. 

 

In lightweight aviation components such as brackets, gaskets, guides, seals, spacers, and washers, high-heat plastics outperform metals by providing thermal and mechanical stability, insulating characteristics, zero flammability, low outguessing in a vacuum, as well as chemical and jet fuel resistance. Make sure to look for the best plastic for aircraft interiors.

 

 

Thermoforming and Plastics Used in Product Manufacturing

Thermoforming is a simple process that involves heating suitable thermo-formable plastic sheets to their 'forming' temperature, and subsequently shaping them into desirable shapes by applying force. This can be done through various methods including using mechanical assist plugs, vacuum and form air. Plastic sheets manufactured through 'extrusion' are the most used raw material in the process of Thermoforming, due to higher flexibility and control during the process. Once the material reaches the optimal forming temperature, it's transported to the forming station and the mold is closed upon the pliable sheet for it to attain the desirable shape.

Thermoforming has limitless applications in the current world, with the ever-increasing need for re-usable plastic materials. From thermoform disposables to medical- packaging, these materials come in handy due to their lightweight and convenient availability.  

Common uses of Thermoform Plastics 

●     Retail clam shell packaging

●     Packaging blisters

●     Pick and place trays

●     Material and handling tray and cover

●     Shipping trays

●     Medical packaging

●     Pop displays

●     Packaging inserts

 Brief view into the popular Thermoformable plastic sheets used- 

ABS Plastic (Acrylonitrile Butadiene Styrene)- Due to its tough and dependable resistance to elements like heat, this thermoformable plastic sheet can be easily molded at high temperatures. It's commonly used for mechanical purposes like plumbing, and can also be employed in making protective headgear, golf club heads, musical instruments like recorders, and for toys like LEGOs. This plastic can also be used in several tattoo inks. 
HIPS Plastic (High-Impact Polystyrene)- It can be used for foamed or rigid plastic. It is quite cost-efficient and is available in various colors. This plastic forms very easily making it a popular choice for thermoforming processes. As compared to ABS, HIPS plastic is clearer and brittle.  Hips plastic sheets are used for forming materials for protective packaging for food and drink items, clam shell containers, disposable cutlery and bottles. 
HDPE Plastic (High-Density Polyethylene)- This thermoformable plastic is a stronger version of HIPS Plastic and is comprised of petroleum. Due to its exceptional strength and high density, this plastic can be used for diverse applications, including making plastic bags, hula loops and even fireworks, water-pipes and cable-installation.
PVC Plastic (Polyvinyl Chloride)- This is the third-most used plastic in thermoforming processes. The manufacturing process consists of 'suspension polymerization', giving this plastic a strong, rigid and hard structure. This rigidity gives this plastic the ability to with- stand high temperatures and pressures. It costs less, making it a lucrative option. It can be efficiently used in manufacturing sewage pipes, commercial signage, electric cables, flooring, faux leather clothing etc.
PET Plastic (Polyethylene Terephthalate)- This clear and low-cost plastic is one of the most used thermoformable plastics. The most common use of this plastic can be seen in food-packaging and bottle production, as its FDA approved and hence safe to use. It is also used in synthetic fiber production. PET plastics have a great resistance to external elements as they are dried after being thermoformed and molded. The most appealing feature of PET plastics in our world where plastic accumulation is one of the largest concerns, is their great ability to be easily recycled. This makes them a profitable, yet eco-friendly option. 
PETG Plastic (Polyethylene Terephthalate Glycol)- PETG plastics are a variation of PET plastic. These are used for blister-packaging and in making trays. Just like PET this material is clear and has great impact strength.

In addition to the above mentioned thermoformable plastics, various other options are available, with an equal quantity and quality of resourcefulness and utility. These include plastic sheets made from Acrylic, LEXAN, Pennate, Royalties, Vinyl among various others. Their different properties make them eligible for different applications and although there can be various drawbacks, it cannot be denied that our daily life can get dangerously impacted in their absence. The need of the hour is not to get rid of plastic- consumption, but to legislate and execute an impactful strategy of reduce, reuse and recycle. This will help us improve our standards of living, while taking care not to hamper the processes of environmental sustainability and stability.

Types of Thermoplastic Materials- Selecting The Appropriate FAR Rated Plastic

Thermoplastic materials are popular due to their user-friendly safe processing, these can be melted and shaped into anything and everything because of their unique chemical properties. Some high resistant plastic can be classified and rated as FAR or flame-retardant plastic emitting low heat and smoke density. This property makes it non-inflammable or inherently self-extinguishing, making them suitable for use where fire protection is an issue.

Thermoplastics are used for a wide range of applications from consumer goods to medical equipment, depending on the type of material. From manufacturing plastic parts and components for all kinds of applications, the injection molding for thermoplastic allows almost any shape to be created, meeting almost every manufacturing need.

However, it should be noted that with a wide range of thermoplastics it is not quite a case of 'one size fits all'. So choosing the right materials for the job is a crucial step of the plastic injection molding process cycle.

To make this simple for you, we have narrowed down the characteristics and properties it has to offer:

●     This plastic can be remolded and recycled without any damage.

●     These are easy to mold and shape.

●     It is lightweight and offers high strength.

●     Because of the commendable properties, these are used in aircraft in place of the metals.

●     Cost-effective because of the low processing cost.

●     High volumes of parts can be manufactured easily.

●     Chemical, flame, and impact resistance.

●     More environmentally friendly than other plastics as it can be recycled.

How to select the correct resin grade for your application?

The resin grade of thermoplastics whether you are looking for knife sheath plastic or plastic to meet more stringent FAA inflammability requirements, types falls into three different grades, commodity, engineering, and high performance or specialty of the material. When selecting a plastic to use, you should review the grade that is appropriate to your application and has the performance requirements your finished product must meet. Choosing the right resin grade can make or break the application.

So here we have narrowed down the two resin grades you need to know: 

1. When looking for a budget-friendly option, commodity resin can offer a variety of uses when it comes to plastic injection molding. These thermoplastics are produced at a high-volume and low cost for common items where impact-resistant mechanical properties are not required. These types of resins include:
1. For easy processing and highly moldable material Polypropylene works best.
2. For lightweight, corrosion-resistant, and highly flexible material Polyethylene is the best choice.
3. For a flame retardant and expandable material, polystyrene can be the material of choice.
2. Looking for a potential substitute for metal parts? Engineering resins are commonly used for durable goods, especially in industrial applications. Plus, these offer better thermal, chemical, and mechanical properties as compared to commodity resin. Below are the types of thermoplastics under this grade:
1. With high impact strength and chemical resistance, ABS is known for its excellent ductility.
2. Shatterproof and high strength, PET is known for its high resistance to water.
3. Polycarbonate is useful in applications requiring a high level of transparency and is extremely lightweight.

If you are looking for a thermoplastic sheet designed to meet FAA flammability requirements and higher in-service temperature applications, Boltaron can be a reliable choice. They offer excellent impact strength, abrasion resistance, stain, and chemical resistance materials available in the industry's greatest selection of colors, textures, and designs.

Not sure what material will meet the requirements of your project? Don't worry you can find ample information on the website of a reliable manufacturer. On the contrary, if you have any questions or queries it is best to get in touch with experts. Here is a rundown few series of materials that Boltaron offers:

• Simona Boltaron 4330 series is a fire-retardant PVC sheet that meets stringent FAA flammability requirements.
• The 6800E series is an ABS or PVC sheet that is also FAR rated while offering excellent impact strength.
• The 9816 series is a rigid sheet used in aircraft applications that meets FAR for low heat release and smoke density.

Types of Plastic In A Thermoforming Process

For understanding the world of plastics and types used in thermoforming, we must understand the process first. The thermoforming process involves heating the concerned material at the forming temperature so that you can apply the required pressure on the sheet to take the desired shape by filling in cavities of the frame. There are three different types of forces that you can apply for getting the desired shape of the plastic, namely, manual assist, vacuum, and form air. There are about six types of plastics used in the industry for thermoforming methods: ABS, HIPS, HDPE, PVC, PET, and PETG. You can make about anything with the suitable types and frames for the plastic.

Properties for each type of plastic

ABS plastic: ABS plastic stands for composition made of three materials, namely acrylonitrile, styrene, and butadiene. With the right combination of these materials in the formation of plastic, you will get a composite that is resilient to a lot of external factors. It can handle temperatures ranging from -4 degrees Fahrenheit to 176 degrees Fahrenheit. This property makes the plastic quality durable for a lot of uses in various industries. Some of the common examples of the services are protective headgear, golf club heads, musical instruments, like recorders, and even for toys, like Legos. You can also use this plastic in some tattoo inks.

HIPS plastic: HIPS plastic or polystyrene is popularly known as rigid plastic. It is easily transferable into known formats but is brittle and transparent in nature. This defining property makes it a popular pick for disposable cutlery with takeouts. One time use bottles and containers. Manufacturing companies like using this to protect edibles like chips, peanuts, food, and other drink items. Since it is a budget variant of plastic, most people love the idea of high in demand products that need reinforcements now and then.

HDPE plastic: It is a popular variant of the HIPS quality that is comprised up of petroleum. It contains a high density of polyethylene. Since this variety of plastic has an excellent strength to density ratio, it makes the plastic idea for various uses. It helps make the installation pipes in the construction business. Manufacturing units use this plastic in the upper layer of the cables. It is also widely used in making plastic bags as well as bottles for daily use.

PVC: Another typical example of a plastic that is probably in the top three used polymers in the field. It is made up of suspension polymer that makes the plastic useful for making things that can withstand high temperature and pressure. It has a strong heard structure with a rigid outer surface. This property makes it viable for many uses like sewage pipes, commercial signage, electric cables, flooring, faux leather clothing.

PET plastic: It is primarily used in the production of bottles across the globe. The distinctive property of this plastic is that once you have molded the surface in the desired shape, you need to dry it further before you can put it to regular use. It helps in increasing the resistance of the product. It helps in keeping the outside elements from tampering with the liquid or any other edible inside. You can also recycle PET plastic, which makes it one of the most popular options for production in the industry.

Thermoplastics Replacing Other Materials

When comparing thermoplastics with other conventional materials, for modern and innovative designs, the thermal stability and strength are comparable, but the advantage to using thermoplastics by most companies across several industries is its high impact resistance due to the flexible nature of polymer chains. This means that any product produced using thermoplastic will be more resistant to breaking, have less damage during crashes, and overall safer than the products designed with materials like metal.

Thermoplastics are plastic polymers that are well suited for many applications. When they are heated allowing for molding, these can easily cast into any shape or texture and will eventually harden upon cooling. When frozen these become brittle almost like glass and are more likely to break or fracture. Moreover, because of the unique chemical properties of thermoplastics material many automotive companies use it in the production of parts as it can be remolded and recycled without affecting the end material and its properties. Let's take a look at what makes it a material of choice among industries:

Variety of design options to choose from:

The forming of thermoplastics gives the manufacturer and the company a lot more control over the final shape, texture, and finish on the surface. The forming of thermoplastic can be created into a slick, hard finish, a slightly soft surface, or anything in between depending on the material and techniques used during molding.

Plus, you can easily customize it and make something extra-ordinary when you need a product to bounce or have little give for comfort. Formulating a thermoplastic material by adding other co-polymers can amplify the effects while allowing you to get any finish you want.

Better resistance to chemicals:

Thermoplastics are compatible to be used in medical device manufacturing, automotive, to aerospace industry. The same feature helps the material to resist other chemicals and weather conditions without chipping, melting, or cracking easily. That means that the part has a longer lifespan than parts made from other materials. Chemical resistance and durability are the main reasons for companies choosing thermoplastics in the first place. And, because these are extremely lightweight, they are a popular choice when weight is a factor in your overall design. Especially, in the aerospace industry, these have eventually replaced the metal parts, making them durable and a lightweight alternative for heavy materials.

For instance, there are dozens of caps, fittings, tanks, and other parts that are in constant contact with both mechanical shocks, reactive chemicals, and different weather conditions. So it is important that you choose thermoplastic for several parts to ensure that these handle all the challenges of engine or body panel use. Moreover, when certain co-polymers or additives are blended with thermoplastics these can meet certain performance standards and compliance requirements.

Provides flexibility and efficiency in production:

The thermoplastic manufacturers have advanced in manufacturing products made from thermoplastics which also allows aircraft and automotive manufacturers to take advantage of the unique properties of thermoplastic material. The fact that thermoplastics have unlimited shelf life, reduces waste during manufacturing and increases efficiency during the production activities.

Thermoplastics can be recycled:

As thermoplastics can be recycled, that means it supports environmental and sustainability efforts. When a flash occurs, which contributes the need to trim the material to fit the required part or when some parts fail and be rejected. In this case, the material can be melted and molded into a new form, allowing for mistakes to be corrected and repairs to be made flexibly. Rather than being discarded or increasing wastage, which then adds up the cost, even on those small portions from runner or trims made to size, the thermoplastic material can be easily recovered by melting and repurposed for another demanding application.

Use of Thermoplastic for Airplane Interiors

In recent years, the use of plastic for aircraft interiors has surged in demand to achieve weight and cost-saving. According to a report, thousands of kilograms of thermosets composites are already used for cabin interiors in every commercial jet, due to the neat and reinforced high-performance engineering thermoplastics that make it a natural fit for the aerospace industry compared to other industrial materials. Common applications including floor, ceiling, door, sidewall panels, overhead storage bins, window surroundings, ducting, partitions, and much more.

Thermoplastics with their introduction have proved to be beneficial and initially started to replace aluminum and titanium fasteners as well as smaller structural elements present in the interior of the Aircrafts. While enhancing the interior overall, this surge in demand is attributed to several benefits.

●   Replacing metals with lighter grade plastics such as Simona Boltaron’s 9000 and 4000 Series materials, a family of high impact materials that meet Federal Aviation Administration requirements for flammability, smoke, and heat release for aircraft interiors not only makes economic sense but also helps to reduce the environmental impact of each flight. Plus, plastics used for aircraft interiors have the durability and chemical resistance required for aircraft interiors, it also provides flexibility for improving the appearance of the cabin for more complex shapes or fittings.

 ●  Thermoplastics are very durable. During use, these are resistant to scratches and nicks that might result from the foot traffic, prolonging the aircraft interior’s new appearance. Plastics can also withstand hostile environments with intense temperatures, making them an ideal material for airplanes that have to experience a wide range of conditions. Though, hostile environments aren’t always made so by temperatures it also involves exposure to harsh chemicals. For instance, the high chemical resistance of thermoplastics means that it can be completely functional even when it is submerged in a severe chemical environment where metals have the chance of dissolving and deforming. This dimensional and density stability has made it a favorite for aircraft components, whether for interior, mechanical, or exterior application.

In the aerospace industry, it is important to provide materials that are flame retardant in order to meet very strict regulatory compliance. Plus, there are a multitude of non-regulatory but still important customer needs that plastic has to cover on the inside of the airplane. When compared to air frame parts, the interior may seem to be less demanding structurally but there are a lot of specialized needs and mechanical requirements that have to be met, including very stringent fire, smoke, and toxicity numbers as well as for providing an aesthetic, consistent and durable framework for the overall interior.

 Here are some obvious or unexpected nook and crannies where plastic is used in Aeroplane:

●      Interior wall panels

●      Luggage compartment

●      Aircraft doors

●      Ventilation ducting and seals

●      Wiring conduits

For the weight-conscious applications, especially in the aircraft interiors, thermoplastics high strength-to-weight ratios make plastic compounds ideal. As the components are now ten times lighter than their metal counterparts there is also an increase in fuel-efficiency.

Advances in thermoplastic manufacturing and processing have allowed for great flexibility to design revolutionary aircraft layouts that are not only ergonomic but more aesthetically pleasing as well. Thermoplastic is much easier to mold and can be machined into geometrically complex parts while being much lighter and just as safe as materials like rubber and aluminum. It can be machined to extremely tight tolerances which can be critical for aerospace applications. All-in-all, especially for application in aerospace sectors the main reason behind the success of the material is its flexibility and customization. Thermoplastics for aerospace are built with specific properties in mind, including shock resistance, flame retardancy, high strength-to-weight, and low smoke and toxicity, offering a multitude of benefits. So, adding the right adhesive can help you incorporate more plastics into the production line of aircraft so everyone can experience added values.