Collins Aerospace Partners with AFRL to Develop Innovative Thermoplastic Wingtip for F-16

Collins Aerospace has been chosen by the Air Force Research Laboratory to receive a contract grant to develop an innovative high-impact resistance F-16 ventral fin utilizing Collins’ thermoplastic welding methodology, which will considerably decrease both the weight and expenses associated with the existing design.

Collins is committing around $100 million over the next five years towards the enhancement of its thermoplastic technology and intends to certify and process thermoplastic materials for military and commercial applications. Under the three-year agreement, the proposed initiatives include the application of a specialized welding technique, component design, and prototype creation for the F-16 ventral fin. The project will utilize best practices from analogous programs, including the recent composite-based F-16 horizontal stabilator.

“We are witnessing a growing need and opportunity to replace outdated aircraft components with thermoplastics,” stated Stan Kottke, vice president and general manager of Aerostructures for Collins Aerospace. “The trend is to employ advanced thermoplastic materials to diminish costs and weight while minimizing our overall environmental impact, with these advantages directly benefiting our clientele.”

Utilizing automation techniques on the manufacturing floor, cost savings are anticipated to exceed 30% where Collins can implement thermoplastic composite materials. Thermoplastic resin is naturally more durable than thermoset resins commonly used in production. Superior materials reduce the overall weight, enabling a sleeker design and enhancing payload range. Thermoplastic materials offer an indefinite shelf life, can be stored at ambient temperatures, and are capable of being reused or recycled. This negates the necessity for energy-intensive cold storage, which is mandatory for thermoset raw materials.

The subsequent phase entails advancing and refining the distinct designs and manufacturing technologies applicable to shaping and thermally joining thermoplastics for component assemblies. This task will be executed within the Riverside composites center.