Breakthrough! New carbon fiber reinforced PEKK composite components
Hexcel recently showcased a new carbon fiber-reinforced PEKK composite part developed jointly with Arkema, unveiling a breakthrough in thermoplastic composites.
Back in 2018, Hexcel and Arkema signed a strategic collaboration agreement. As part of the Helues project, the two companies are committed to combining Hexcel's expertise in carbon fiber with Arkema's expertise in PEKK to develop thermoplastic composite solutions for the aerospace industry.
Funded by the German Aerospace Center (DLR) and supported by the Bavarian Ministry of Economic Affairs, the Helues project brings together partners such as Airbus Helicopters Deutschland GmbH, Neue Materialien Bayreuth GmbH, Christian Karl Siebenwurst GmbH & Co. KG, and Incoe. The project pioneered a new, world-first manufacturing process for high-temperature thermoplastic composites, centered around one-step molding and overmolding.
Using HexPly® carbon fiber-reinforced Kepstan® PEKK unidirectional tape and Kepstan™ PEKK injection molding compound, the technology enables the rapid production of complex structural parts containing stiffeners and functional elements in under two minutes.
New materials and processes offer three key advantages to aerospace OEMs:
Composite component production cycles are reduced from hours to minutes, enabling production of 80-100 jets per month;
The reshapeability and weldability of thermoplastic composites significantly increase design freedom and achieve weight reduction;
The reprocessability and reusability of thermoplastic composites enhance product sustainability and recyclability.
The Helues project's overwing emergency exit prototype replaces traditional assembly structures with an integrated design, reducing the number of components and process steps by 90%. Test results demonstrate excellent bonding between the stiffeners and the thermoformed laminate, further validating the component's feasibility in the demanding aerospace service environment.
With the continued development of high-volume manufacturing and automated, sustainable assembly lines in commercial aviation, the adoption of thermoplastic composites is accelerating. By reducing reliance on energy-intensive autoclaves and enabling robotic manufacturing, the Helues project solution demonstrates the ability of composite material innovation to enable breakthroughs in both performance and mass production for next-generation aircraft.