Putting Science to Work: DuPont Innovations Lift Airbus A380

Made from DuPont™ Nomex®, fireproof honeycomb structures are inherently strong, yet light in weight.

The world’s largest commercial jetliner made its inaugural visit to the United States yesterday, relying on a host of DuPont lightweight, high-performance materials to lift the first-ever, full-length twin-deck aircraft.  The innovative materials include DuPont™ Kevlar® and Nomex® aramid fibers, Vespel® high-performance materials, Tefzel® fluoropolymer resin, Oasis® composite wire insulation, and Tedlar® PVF film.

An Airbus A380 operated by Lufthansa landed at John F. Kennedy International Airport in New York City at the same time a Qantas Airways Airbus A380 landed at Los Angeles International Airport. The “superjumbo” aircraft has four engines and a flight range of up to 15,000 kilometers – enabling it to fly nonstop between Europe and Asia.

“DuPont innovations have helped Airbus’ concept of the world’s largest aircraft to become a reality,” said Jim Weigand, global business director, DuPont Advanced Fiber Systems. “Since the infancy of aviation, DuPont has been delivering unique materials essential for lighter weight, reduced volume, durability, energy efficiency and environmental resistance.  Our work with Airbus is another example where DuPont science and technology provides unique solutions to the aerospace industry and the broader marketplace.”

DuPont advanced fibers, electronic components and composites are assisting Airbus to meet demanding strength and weight requirements, as well as stringent safety standards.  The A380 and the aeronautics industry require products with a complex combination of properties: strength and durability, lightweight, resistance to harsh environments, and ease of use in manufacturing.  Safety considerations, such as flame resistance, also are important to the industry.

The new Airbus A380 includes a new honeycomb composite made from DuPont™ Kevlar® which is found from its flooring to interior walls to wing flaps.  Pound for pound, Kevlar® is five times stronger than steel.  As a honeycomb core, this strength allows the Kevlar® to dramatically increase the structural integrity of the aircraft, while enabling a substantial weight savings.

The A380 uses engine parts made with high-strength, lightweight Vespel®, which reduces weight in the A380 by replacing heavier components made from metallic alloys and by reducing friction to allow for lower-weight actuators. Virtually every jet engine made in the Western world uses Vespel® parts.