Airplane seats aerospace approved

Thermoplastic Solutions for Aircraft Interior Applications

Lightweight construction, safety and production readiness

Ensinger supports the aerospace industry with engineering and high-performance thermoplastics as well as thermoplastic fibre-reinforced composites for demanding interior applications that have been tested in accordance with FAR 25.853. Our materials open up freedom in the engineering and design of proven cabin components through to lightweight, structurally relevant concepts.

In doing so, we combine application-oriented material selection with reliable processing and cost-effective implementation, from semi-finished product to finished part.

Application examples Fire protection (test methods) Materialsolution One-Stop Shop

Your Advantages at a Glance

  • Weight-optimised designs:
    Selected thermoplastics have a lower density than aluminium and can therefore support lighter component designs.
  • Flame-resistant materials:
    Documented testing in accordance with FAR 25.853 – depending on the material, test method and tested material thickness.
  • Economical manufacturing:
    Fewer post-processing steps, functional integration and efficient processes can reduce overall effort and costs.
  • From development to series production:
    Support throughout the process chain, from material selection to a component solution designed for manufacture.
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Material Solutions for the Aircraft Cabin and Cockpit

Whether seats, lighting, galley or cockpit equipment: components in aircraft interiors must meet high requirements for safety, weight, function and durability. Ensinger offers a broad portfolio of thermoplastics and thermoplastic composites for a wide range of component concepts.
Overhead storage and lights
Seats of airplanes
Airplane high wing flap

Cabin Systems

Passenger Cabin & Crew

Functional Components

Cockpit & Crew

Air management

Seat shells, armrests and seat trims

Galley and lavatory applications

Control yoke 

Drinking water system

Tables and tray-table components

Brackets and further functional components

Rudder pedals 

Lighting systems and light housings

 Overhead storage
 Hinges, latches and handles
 Crew seats, Crew-test areas
Sensor, switch and electronics housings Wardrobe, partition and trim components Guide, sliding and wear components
 Emergency handles

Heat sink

made of thermally conductive PPS

LED heat sink made from thermally conductive PPS
LED chips must be placed on a heat sink, which is often made of Aluminium. Replacing the aluminium heat sinks with thermally conductive plastic profiles reduces weight and life cycle costs. Plastic profiles don't need corrosion protection and no grounding.
J-Hook

J-Hook

made of TECATEC PEI GW50 natural composite plates

Structural component for an airplane seat («J-hook»)
The aircraft industry exacts the highest requirements for installed materials: Low weight, high mechanical properties, fatigue resistance as well as stringent FST requirements are mandatory. Aircraft interior applications often see the use of glass fibre reinforced polyetherimide (PEI).
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Fire Protection in Aircraft Interiors: FAR 25.853

Depending on the installation location and component function, materials for aircraft interiors must meet defined fire-protection requirements. FAR 25.853 specifies, among other things, flammability tests. For certain interior components, requirements for smoke density, combustion toxicity and heat release may also be relevant.

Ensinger offers materials with documented testing in accordance with FAR 25.853. The evidence relates in each case to specific materials, test methods and tested material thicknesses. Test documentation is available on request.

 Relevant Test Methods at a Glance

Test description

FAR 25.853 

Airbus ABD 0031    
specification 

Boeing
specification
Flammability
60 seconds Vertical

FAR/CS 25.853 (a), App. F, Part I, (a)(1)(i)

  AITM 2.0002A  BSS 7230 F1
Flammability
12 seconds Vertical

FAR/CS 25.853 (a), App. F, Part I, (a)(1)(ii)

  AITM 2.0002B  BSS 7230 F2
Horizontal flammability,
15 seconds, 2.5 in/min   

FAR/CS 25.853 (a), App. F, Part I, (a)(1)(iv)

  AITM 2.0003A  BSS 7230 F3
 Horizontal flammability,
15 seconds, 4.0 in/min

FAR/CS 25.853 (a), App. F, Part I, (a)(1)(v)

   AITM 2.0003B  BSS 7230 F4
 Smoke Density (NBS)

FAR/CS 25.853 (d), App. F, Part V

  AITM 2.0007A & B  BSS 7238
 Smoke Toxicity N/A  AITM 3.0005  BSS 7239
*The test applicable to a component depends on the installation location, design and requirements of the respective aircraft manufacturer. Material testing does not replace evaluation or approval of the finished component or assembly. 

Thermoplastics and Composites for Demanding Interior Concepts

Engineering and High-Performance Thermoplastics

Our portfolio ranges from flame-retardant engineering plastics to high-performance thermoplastics for demanding mechanical, thermal and functional requirements. This enables material selection to be aligned specifically with component function, loading, processing route and required tests.

  • TECAPEEK
    PEEK-based high-performance materials, also fibre reinforced or tribologically modified
  • TECAPEI
    polyetherimide for demanding applications
  • TECATRON
    PPS-based materials with high resistance
For selected materials, documented tests are available for vertical and/or horizontal flammability and – depending on the material – for smoke density, smoke toxicity or heat release.

Thermoplastic Composites

Where high stiffness at low weight is required, thermoplastic composites expand the range of solutions. They combine continuously fibre-reinforced fabrics, for example carbon or glass fibres, with a thermoplastic matrix.

The result: material concepts with a favourable strength-to-weight ratio for conventional interior components, functional parts and lightweight structural concepts. Ensinger offers thermoplastic composites as:

  • Semipregs
  • Prepregs
  • Organosheets
  • Compression moulded composite sheets
These semi-finished products provide a suitable basis for prototypes, small series and industrial series production.
Polycarbonate-based materials:
PEI or PES-based materials:

From Semi-Finished Product to Ready-to-Install Component

Our expertise does not end with the material. Ensinger supports development with a broad process chain – tailored to requirements, component geometry and target production volume.

Possible Services and Processes:

  • Material and application advice
  • Compounds and semi-finished products
  • Profiles and customised tubes
  • Thermoforming and direct forming
  • Overmoulding and injection moulding
  • Machining
  • Thermoplastic composite solutions
  •  Component-specific design and implementation suitable for manufacture
By combining materials expertise, semi-finished products and processing technologies, development times can be reduced and material, component and manufacturing requirements can be brought together at an early stage.

Your Application. Our Material Solution.

Contact for information about plastics for aerospace
Are you developing a component for an aircraft interior, looking to replace metal or seeking a material with documented fire-protection evidence? Download our brochure or contact our experts.Our specialists will support you in selecting and designing a suitable solution.
Contact us at [obfemailstart]YWVyb3NwYWNlQGVuc2luZ2VycGxhc3RpY3MuY29t[obfemailend] or via our contact form.
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Aerospace: Solutions for aircraft interiors applications

Discover more of Ensinger

From orbit to mission-critical defence applications: discover our high-performance plastics for extreme requirements.

FAQs

  • The statement relates to defined tests on a specific material at a specified material thickness. Depending on the material, tests for vertical flammability, smoke density, smoke toxicity or heat release may, for example, be documented.
  • No. The use of a material must always be assessed in the context of the component, installation location, design, wall thickness and the specifications of the aircraft manufacturer. Material tests provide an important basis for component development, but do not replace approval of the finished component or assembly.
  • The range extends from seating and lighting components to air and drinking-water systems, as well as galley, lavatory, luggage-compartment and cockpit components.
  • Yes. Ensinger offers thermoplastic composites as semipregs, prepregs, organosheets and composite sheets, as well as support from the semi-finished product through to component-specific implementation.