The sustainability aspects of aviation are under constant scrutiny, particularly the business jet travel sector, due to its higher per-person carbon footprint compared with commercial airliners. Making smart material choices to reduce the weight of an aircraft is essential to lessening the environmental impact of private aviation, reducing total fuel burn.
A recent development comes from Plastika Balumag, a Switzerland-based thermoforming company working in the aviation sector, manufactures products including a formed, self-insulating air duct assembly, which optimises air circulation through the on-board ventilation system. Conventionally, ventilation circulation systems are comprised of rigid ducts, derived from heavier polycarbonate materials, and separate insulation products, which add further weight.
The company recently decided to make its air ducts from Zotek F OSU XR technology from Zotefoams, a foam manufactured using naturally inert polymer materials, with fire, smoke and toxicity properties that meet aviation standards. This extra-rigid closed cell crosslinked foam has structural and semi-structural capabilities, and is used extensively by aircraft manufacturers for items such as window seals, soft-touch trims, close-outs, insulation, carpet underlay and environmental control systems – and now also for Plastika Balumag’s air ducts.
Patrick Gyax, chief technology officer at Plastika Balumag, says the foam technology has enabled a weight reduction of up to 50% in its formed, self-insulating air ducts, compared to using some other materials such as conventional polycarbonates, which would require the ducts to have separate insulation. Zotek F is also strong, enabling Plastika Balumag to achieve the same performance at lower densities, which reduce weight even further.
“As well as being half the weight of usual plastic air ducts, they also deliver exceptional acoustic and heat insulation,” said Gyax. “In addition, they also meet stringent certification requirements for aircraft interiors, including full compliance with all smoke density and heat release requirements.”
Zotefoams is exhibiting at stand 7A57 at Aircraft Interiors Expo 2024, taking place from 28-30 May.
