At the Paris Air Show, Hexcel [NYSE: HXL] is spotlighting a major leap in thermoplastic composite technology—a new PEKK/carbon thermoplastic component developed through the HELUES project, a collaborative initiative focused on next-generation aerospace manufacturing.
Back in 2018, Hexcel formed a strategic alliance with Arkema to co-develop thermoplastic composite solutions for aerospace by combining Hexcel’s carbon fiber expertise with Arkema’s knowledge of PEKK (polyetherketoneketone).
At this year’s show, the result of that alliance is on full display through a HELUES demonstrator—a structural component for an overwing emergency exit door, representing a key innovation in high-rate aircraft production. The part exemplifies a new manufacturing process aimed at transforming how complex aerospace structures are built.
“The HELUES demonstrator is a milestone in aerospace thermoplastic composites,” said Thierry Merlot, Hexcel President Aerospace Europe, Asia Pacific, Middle East, Africa & Industrial.
“By eliminating autoclaves and enabling functional integration in a single step, thermoplastics are opening the door to truly scalable aircraft production.”
As demand rises for efficient, high-volume aircraft production, especially for single-aisle jets, Hexcel and its HELUES partners are helping OEMs address these needs through material innovation and process integration.
The HELUES project—funded by the Bavarian State Ministry of Economic Affairs and supported by the German Aerospace Centre—includes collaborators like Airbus Helicopters Deutschland GmbH, Neue Materialien Bayreuth GmbH, Siebenwurst GmbH & Co. KG, INCOE International Europe, ARKEMA, and Hexcel.
At the heart of the project is a one-step forming and injection overmolding process. It uses HexPly® unidirectional carbon fiber-reinforced Kepstan® PEKK tapes and Kepstan® PEKK injection molding compounds to form a fully integrated structural part with reinforcing ribs and functional elements—all within two minutes.
Thermoplastics: Three Key Advantages for Aerospace OEMs
- Significantly reduced cycle times, from hours to minutes—supporting production rates of up to 80–100 jets per month.
- Greater design flexibility and weight reduction, as thermoplastics allow for reshaping and welding instead of fastening.
- Improved sustainability, since thermoplastics can be reprocessed and reused.
The HELUES demonstrator replaces a conventionally assembled door with a single integrated part, cutting component count and assembly steps by up to 90%. Initial testing showed strong material bonding between molded ribs and thermoformed laminates, validating its potential under real aerospace conditions.
With the aerospace sector leaning toward high-rate production and automated, sustainable assembly lines, thermoplastics are gaining traction as a material of choice. By removing energy-intensive autoclaves and supporting robotic manufacturing, the HELUES project showcases how composite innovation can deliver both performance and scalability for the future of aviation.