Foam for Aircraft Innovation
Innovation in the foam sector is ongoing, and over time foam's capabilities are being recognised in new industries and applications. Significant research is also under way in sectors that already use a wide range of foam products. Alongside the extraordinary work happening in space, detailed research is also taking place in aviation.
Why the aviation industry is going lightweight
With environmental considerations rightly at the top of the agenda, the aviation industry is seeking new ways to cut carbon emissions. As it's difficult to encourage a natural reduction in air travel, the industry is taking a different approach: making commercial planes lighter to reduce the fuel burned over a given distance. Over many years there have been significant developments in the foams used in commercial upholstery, including specialist foams designed to meet safety and regulatory standards for commercial vehicles, and these are becoming increasingly lightweight.
New foams in aircraft
Several types of foam are making their way into new aircraft. Aviation materials have long had to meet standards for thermal, fire, toxicity and smoke performance, and newer standards also assess weight-saving credentials. Some UK-based manufacturers have recognised the potential of fire-retardant closed-cell polyethylene (PE) and polyvinylidene fluoride (PVDF) for their lightweight, fire-resistant qualities. Our guide to foam fire safety standards explains the regulatory side.
How these foams are made
In many manufacturing processes, chemicals are used to expand foam into the honeycomb structure we know. The key to these improved foams, though, lies in the process itself: to give PE and PVDF foams their distinct structure and fire retardance without heavy chemical additives, nitrogen gas is used to expand the material, as nitrogen is inert and non-flammable.
The future of foam in aviation
The most versatile and popular new foam is PVDF, known for weight reduction of up to around 50% compared with silicone. In new and refurbished aircraft it's used for trimmings, insulation, carpet underlay and window seals, and is gradually being implemented in overhead bins, tray tables and armrests, with some testing showing reductions of up to 70% against previous materials. As aviation becomes more competitive and environmental penalties rise, experimentation with foam is increasingly common, with PVDF, polyethylene and nylon foams now at the forefront of innovation. The industry is focusing less on outer aircraft design and more on cost and efficiency savings in interior structures – and it's good to see foam's versatility recognised in such an essential part of modern travel. For more, see our guide to polyurethane foam innovation.
For more on eFoam's specialist foams, please contact one of our advisers.
Frequently asked questions
What foam is used in aircraft?
Fire-retardant, lightweight foams such as closed-cell polyethylene (PE) and polyvinylidene fluoride (PVDF). They're used for trimmings, insulation, carpet underlay and window seals, and are increasingly found in overhead bins, tray tables and armrests.
Why is the aviation industry using lighter foam?
To cut fuel burn and carbon emissions. As reducing air travel itself is difficult, the industry focuses on making planes lighter, and new material standards now assess components on their weight-saving credentials alongside thermal, fire, toxicity and smoke performance.
What is PVDF foam?
Polyvinylidene fluoride foam is among the most popular new aviation foams, offering weight reduction of up to around 50% compared with silicone. It's expanded using nitrogen gas, which gives fire retardance without adding heavy chemical components.
