PARIS- Airbus and Boeing are laying the groundwork for unprecedented production increases for their next generation of single-aisle aircraft. They are targeting rates of up to 100 planes monthly each as they explore advanced plastic composite materials and robotic assembly methods, according to industry sources.
Thermoplastics represent a potential breakthrough technology that both manufacturers are actively exploring. Unlike thermoset materials, thermoplastics can be reheated and reshaped after initial forming.
Photo- Niklitov; Wikimedia CommonsAirbus and Boeing Production Output
While both manufacturers face weakened supply chains and extended timelines for next-generation engine development, they shared significant progress on future materials research during a recent Paris composites conference. The research aims to replace the aluminum-based construction that has dominated their bestselling Boeing 737 and A320 aircraft families.
“The goal is to recommend the best approach to transition to the next aeroplane programme,” explained Randy Wilkerson, Boeing’s representative for NASA’s High-Capacity Manufacturing (HiCAM) research project, during the JEC World conference.
Thermoplastics: The Game-Changer
Traditional thermoset composites, already used extensively in larger aircraft like the Boeing 787 and Airbus A350, require time-consuming processing in pressurized autoclave ovens. This manufacturing constraint limits production speeds for smaller aircraft, where volume requirements are substantially higher.
Thermoplastic composites are emerging as a revolutionary advancement. These materials differ from traditional thermosets by maintaining the ability to be heated again and reformed after their initial production process.
“You can melt it and reshape it in any way you like,” explained Lukas Raps of German Aerospace Centre DLR, highlighting the material’s versatility for creating seamless aerodynamic structures.
“There is no doubt that thermoplastic materials offer opportunities that we don’t have with thermoset.”
York Roth, Senior Researcher, Airbus Germany (emphasizing the material’s potential)
Photo- AirbusManufacturing Approaches Under Development
The companies are investigating several production methods beyond traditional autoclave curing:
- Enhanced thermoset systems with accelerated curing times, which Wilkerson described as “a lower risk approach but has a lot of potential”
- Resin infusion techniques that could eliminate autoclave requirements for certain components
- Advanced welding methods using ultrasound instead of traditional rivets, reducing weight and assembly time
During the conference, Airbus, GKN and partners showcased sections of the world’s largest thermoplastic fuselage structure as a technology demonstrator. “This demonstrator was never meant to fly, but it has been established to maximise learning,” Roth told attendees.
Photo- Wikimedia CommonsAirbus and Boeing Production Capacity Limitations
Industry sources revealed that both manufacturers are preparing suppliers for potential production rates reaching 100 aircraft monthly each—far exceeding Boeing’s current output and surpassing Airbus’s repeatedly delayed target of 75 monthly.
Analysts note that manufacturing capacity will become as critical a competitive factor as aircraft design in the future commercial aviation landscape, particularly as Western manufacturers face increasing competition from China.
Neither Boeing nor Airbus provided official comment on specific production targets, and officials emphasized no immediate plans exist to launch new aircraft programs—a move that could concern investors already dealing with supply chain disruptions and Boeing’s ongoing challenges.
Any transition to welded structural components instead of traditional titanium fasteners would require extensive certification testing, with industry sources suggesting future aircraft designs will likely incorporate multiple material approaches rather than relying on a single technology.
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