Development of Expanded Polymers for Aeronautical Applications

PROJECT COST:

127 500 $

PRIMA CONTRIBUTION:

25 500 $

PROJECT DETAILS:

The aeronautical sector drives companies such as Hutchinson to continually improve to supply increasingly lightweight products. The manufacturing of various aircraft interior components has recently shifted toward greater use of polymer foams, thereby replacing so-called “conventional” solutions. Expanded polymers provide both lightness and thermal insulation, advantages that are highly valued in this sector. Unfortunately, only a single supplier of expanded polymer is currently qualified by the major aircraft manufacturers, creating a monopoly situation for producers such as Hutchinson.

With the aim of fostering innovation, improving business conditions, and generating higher sales volumes while maximizing profit margins, Hutchinson seeks to develop its own expanded polymer material. The proposed approach encompasses both a proprietary process for producing the expanded polymer and the transformation methods required to manufacture ultra-lightweight foam components.

A project conducted in 2022 enabled the completion of a literature review, patent analysis, and the identification of candidate materials to validate the feasibility of the proposed approach. Preliminary tests were carried out to refine the selection of polymer grades and to establish a functional foaming process that meets technical requirements.

The objective of the current project, led by researcher Michel F. Champagne at the NRC in collaboration with Hutchinson, is to refine the approach, validate it with additional polymer types, and enhance process performance to produce a material with the lowest possible density. Critical properties—including mechanical, thermal, acoustic, and fire-resistance characteristics—will be evaluated and used to optimize both formulations and manufacturing processes. The goal is to develop a proprietary process at Hutchinson that will enable the company to compete effectively on the international stage.

Hutchinson’s market share for aircraft interior components has unfortunately declined in North America in recent years. By staying at the forefront of emerging technologies through mastery of expanded part manufacturing, Hutchinson aims to capture new markets and support job creation in Quebec’s manufacturing sector. Furthermore, during this project, two undergraduate students will participate in the development of ultra-lightweight components.