SpecialFocus

The Future of Flight: Plastics Take Off in Aerospace Innovation
aerospace
by Brody Lewis, Polymer Components
A

t the dawn of a new era of space exploration, aerospace companies worldwide are seeking ways to make their products more efficient, reliable and cost-effective as humanity looks to the stars. Plastics are one of the most versatile materials that aid in achieving this goal of expanding our reach beyond our atmosphere. Plastics’ adaptability across a myriad of applications has led to its integration into almost every new project in the aerospace industry. Plastics offer significant advantages transforming how aircraft and spacecraft are designed, manufactured and operated.

About the aerospace industry
The aerospace industry, a pinnacle of technological achievement, encompasses aircraft and spacecraft design, manufacturing and operation. It is characterized by stringent safety standards, continuous technological innovation, global competition and a significant impact on international transportation and communication networks. However, it also faces pressing challenges such as regulatory compliance, environmental sustainability and the need for continuous research and development to meet evolving demands for efficiency and safety.

Technological innovation is at the heart of the aerospace industry, driving progress in materials science, propulsion systems, avionics and manufacturing processes. Integrating advanced technologies such as artificial intelligence, machine learning and autonomous systems is revolutionizing how aircraft and spacecraft are designed and operated. For example, the development of composite materials, including advanced plastics, has led to lighter, stronger and more fuel-efficient aircraft.

The aerospace industry is highly competitive, with major players from the United States, Europe, Asia and other regions vying for market share. Companies like Boeing, Airbus, Lockheed Martin and Northrop Grumman lead the industry, continually pushing the boundaries of innovation to maintain a competitive edge. Emerging markets, particularly in Asia, are increasingly contributing to the global aerospace landscape, fostering new collaborations and competition.

NASA astronaut Jessica Watkins floating in the International Space Station's viewing window
NASA astronaut Jessica Watkins floats in the International Space Station’s viewing window. A 3D printer aboard the space station allows tools to be printed using design files transmitted from the ground.
Beginnings of plastic in aerospace
Plastics were not used in the aerospace scene until World War II, when leaders pushed for military aircraft to become lighter, more durable and more agile. As metal became scarcer in America, plastics and rubbers found their way into flagship aircraft, giving them a cutting edge on the enemy.

Plastics allowed aircraft to be lighter and more resistant to environmental factors, enhancing durability in combat conditions. Early applications included non-critical parts like interior panels, insulation and components in the cockpit. Their adaptability, however, quickly saw them expanding to external parts and even windows, where acrylics replaced glass, offering better impact resistance and transparency while reducing weight. These advances in plastic applications set the stage for their continued role in aerospace, with innovations developed during the war laying the groundwork for the industry’s ongoing reliance on plastics in the following decades.

Why do plastics fit?
Plastics look to solve some of the most significant barriers to space exploration and travel. Weight reduction is a crucial aspect of space flight, and plastics with low weight and high resilience look promising in filling the gap needed for efficient space flight. Space is also a hostile environment with problems such as extreme temperatures, radiation and micrometeoroids. Plastics, engineered specifically for aerospace applications, offer resilience in these harsh conditions. Plastics can also be recycled, which is crucial when astronauts are in places where raw materials are scarce, such as the moon and Mars.
The future of plastics in space flight
As space agencies and private companies pursue ambitious plans for lunar bases, Mars missions and interstellar travel, the role of plastics is becoming increasingly essential. Known for their versatility, light weight, durability and affordability, advanced plastics are being integrated into nearly every aspect of modern spacecraft. From reducing weight and fuel consumption to enabling sustainable, long-term missions, plastics will transform how we design, build and operate spacecraft.

Theoretically, it takes about 10 pounds of fuel for every 1 pound of cargo to be sent into Low Earth Orbit (LEO), making a payload-to-fuel ratio of about 10%. In the real world, that percentage is much lower. SpaceX’s Falcon 9 rocket, one of the most efficient rockets to date, averages about 17 pounds of fuel for every 1 pound of cargo to LEO. This is a payload-to-fuel ratio of about 5.8%. However, reducing the weight of the overall structure of the rocket while maintaining structural integrity allows for more payload. The name of the game in the aerospace industry is weight reduction, and plastics serve a critical role in achieving this goal.

SpaceX's Starship SN16
SpaceX’s Starship SN16 aims to enable interplanetary travel from its launchpad in Boca Chica, Texas.
Plastics are significantly lighter than metals, which helps reduce the overall weight of aircrafts and spacecrafts. This reduction in weight leads to lower fuel consumption and increased efficiency. Despite being lightweight, many plastics offer high durability and resistance to wear and tear, making them ideal for various aerospace applications. This lightweight nature of plastics contributes to fuel efficiency and the ability to carry more payload or passengers, increasing the operational capacity and economic viability of aerospace missions. As plastics become stronger and lighter, aircraft and spacecraft components will transition from metal to plastic.

High-performance thermoplastics and thermoset resins can be formulated to endure extreme temperature fluctuations, from the intense heat of reentry to the cold of outer space. They also resist corrosion and chemical degradation, allowing them to last longer in environments where traditional materials might fail.

Certain plastics are radiation-resistant, an essential feature for protecting structural and electronic components from cosmic rays and solar radiation. These plastics will help extend the operational lifespan of spacecraft and make them suitable for deep-space missions, where exposure to high radiation levels is unavoidable.

Furthermore, plastics’ insulating properties are ideal for shielding sensitive electronics and life-support systems. Plastics can provide a protective barrier for wiring, instruments and control systems, helping to prevent electrical shorts and other failures that could compromise mission safety. They can also serve as efficient insulators for heat and electrical currents, a valuable property for managing temperature fluctuations in space and protecting equipment from harmful electrical surges.

In manned missions, plastic materials will be vital to creating safe, livable environments for astronauts. Lightweight plastic composites can insulate walls in crew habitats, protecting occupants from radiation and temperature extremes. Plastics can also be used to construct spacesuits, airlocks and life-support systems, helping astronauts maintain safe atmospheric pressure and temperature.

Plastics also offer a cost-effective alternative to traditional aerospace materials, which are generally easier to produce, mold and transport. Lower costs make space exploration more accessible for private companies and national agencies, helping drive innovation and increase the frequency of missions. Furthermore, developing sustainable plastic recycling methods could be essential for reducing waste and reusing resources on extended missions.

In a future where lunar or Martian colonies exist, recycling plastic waste into new materials could provide a continuous source of raw materials for manufacturing essential components, tools and equipment. This closed-loop system would help reduce reliance on Earth-based resupply missions and support self-sustaining human habitats on other planets.

Research into advanced plastic materials is paving the way for innovations that could redefine spacecraft maintenance and durability. “Smart” plastics with embedded sensors can monitor structural integrity in real time, allowing operators to detect weaknesses or damage. This capability is best suited for deep-space missions, where human intervention may not be possible. Self-healing plastics, another promising development, can repair micro-cracks or punctures caused by debris, helping to maintain the structural integrity of spacecraft automatically.

These futuristic materials could eventually be used in spacecraft hulls, habitats and spacesuits, reducing maintenance requirements and improving safety. By enabling spacecraft to adapt and respond to their environment, smart and self-healing plastics could play a critical role in ensuring the success of long-duration missions and deep-space exploration.

In summary
As we continue to explore the cosmos, plastics will be fundamental in creating efficient, reliable and resilient spacecraft capable of supporting human life. With their lightweight nature, durability and adaptability, plastics offer unique advantages for spaceflight that make them irreplaceable. In the coming years, developing new plastic materials tailored to the needs of space exploration will drive progress in the industry, enabling missions that would have once been impossible.

From sustainable habitats on the moon to Mars colonies and beyond, plastics empower humanity to take the following steps into the final frontier. As material science evolves, plastics will remain at the forefront of space innovation, transforming how we design, build and sustain life far from Earth. The future of spaceflight is taking shape, and plastics will play a key role in making interplanetary exploration and colonization a reality.

Brody Lewis a quality control engineer at Polymer Components. For more information, contact Polymer Components at 2166 Parksville Road, P.O. Box 737, Benton, TN 37307-3800, USA; by phone at (423) 338-5882; or online at www.polymercomponents.com.