7 Benefits of Discontinuous Long Fiber (DLF) in Aerospace Manufacturing
Aerospace manufacturing is undergoing a transformation, and at the heart of this change is the innovative use of Discontinuous Long Fiber (DLF) composites. These advanced materials are helping aerospace and advanced mobility industries—from traditional aircraft to eVTOLs (electric vertical take-off and landing vehicles) and UAVs (unmanned aerial vehicles)—reach new levels of efficiency, performance, and sustainability.
1. Lightweight Design for Enhanced Performance
DLF composites provide significant weight reduction compared to traditional materials like aluminum and even titanium. Depending on the application, weight savings can range from 35% to 50% when replacing aluminum, and even more when substituting titanium.
This weight reduction not only improves fuel efficiency but also boosts aircraft payload capacity, two critical factors in the aerospace and advanced mobility sectors. For example, in business jets, DLF was shown to save up to 10 pounds per engine by replacing aluminum guide vanes.
2. Complex Geometries Made Easy
One of the standout features of DLF technology is its ability to create complex shapes through automated compression molding. Unlike traditional continuous fiber composites, which struggle to conform to intricate designs, Greene Tweed's Xycomp® DLF™ delivers an optimal balance of shape complexity and structural integrity. This capability not only simplifies the manufacturing of complex components but also reduces part count and assembly time, streamlining designs for greater efficiency.
Xycomp® DLF™ is a fully characterized material with established design allowables, making it easier for engineers to develop and validate parts with confidence. For aerospace applications such as eVTOLs and UAVs, where compact, highly-engineered components are essential, Xycomp® DLF™ enables the production of parts that were previously unachievable with older manufacturing methods.
3. High Thermal Stability
DLF composites offer superior stability under high thermal stresses compared to many traditional aerospace-grade materials. While aluminum alloy components often suffer a reduction in strength at elevated temperatures, DLF materials maintain their properties at up to 180°C (356°F), making them ideal for harsh operating environments like jet engines and high-altitude drones.
This resilience ensures safer and more durable performance in advanced mobility vehicles that demand high thermal resistance to optimize functionality.
4. Improved Sustainability and Recyclability
Aerospace manufacturers are under growing pressure to adopt sustainable practices. While thermoset composites pose recyclability challenges, thermoplastic-based DLF materials have the potential to be recycled through remelting.
Green initiatives in Advanced Air Mobility (AAM) projects are now exploring the value of recycled composites as a marketable feature, making DLF an attractive solution. Greene Tweed, a leader in thermoplastic composite innovation, is already testing recycled materials for aerospace applications, paving the way for circular supply chains in the industry.
5. Faster, More Cost-Effective Manufacturing
DLF’s automated compression molding process significantly streamlines production by reducing touch labor and operator interaction. Features like automatic fiber placement (AFP) and cobot-assisted deburring increase throughput while maintaining high-quality standards.
Unlike traditional manufacturing methods that rely on labor-intensive machining, DLF can handle multiple components on the same pallet, an innovation that drastically shortens production timelines while remaining cost-competitive.
For aerospace engineers focused on rapid prototyping or production in emerging domains like UAVs and eVTOLs, this efficiency is a game-changer.
6. Enhanced Durability for Critical Components
Aerospace components often endure extreme forces and environmental stressors. DLF composites demonstrate an exceptional ability to meet these demands with features like co-molded designs that enhance impact resistance.
For example, Greene Tweed tested Xycomp® DLF™ designs for outer guide vanes on business jets using a hail impact jig. This advanced testing method, which we discuss in detail in our blog on why we developed the hail impact testing jig, ensures that components can withstand real-world impacts. The combination of metallic leading edges and DLF structures resulted in a lightweight yet highly durable solution, capable of withstanding significant stresses while maintaining performance integrity.
This proves invaluable for parts that are subjected to continuous stress, such as vanes, rotors, and covers in both traditional aircraft and emerging mobility systems.
7. Accelerated Certification and Reduced Risk
One of the common challenges in the aerospace industry is navigating the rigorous certification process for new materials. Greene Tweed's Xycomp® DLF™ not only meets these stringent standards but also comes with pre-characterized, extensively tested data, streamlining the certification process for manufacturers. With ISO and AS 9100 certifications, Greene Tweed ensures the highest levels of quality and reliability, making Xycomp DLF a trusted solution for aerospace applications.
For startups in the advanced air mobility (AAM) sector, where tight deadlines and investor expectations demand proven, ready-to-use materials, Xycomp DLF offers a significant advantage. Already being implemented for use on demanding structural aerospace applications, this material is a more accessible and dependable option.
The Future of DLF in Aerospace
DLF composites, like Xycomp® DLF™, are more than just a material innovation; they represent the future of aerospace manufacturing and advanced mobility. Their ability to address key challenges, such as weight, cost, durability, and sustainability, makes them a perfect fit for next-generation technologies like electric aircraft, autonomous UAVs, and even future space exploration vehicles. Beyond these cutting-edge applications, Xycomp® DLF™ is also ideal for alternative uses such as lightweight, durable aircraft interiors. To learn more about these innovative applications, check out our blog here.
Optimize Your Approach
Interested in learning more about how DLF composites can streamline your projects and drive innovation in your projects? Collaborate with the experts at Greene Tweed to explore tailored solutions for your specific needs.