IntAir · Project

Cheaper, Lighter, Non-Toxic Composite Materials for Aircraft Interior Parts

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The panels and parts inside airplane cabins are made from a type of plastic reinforced with glass fibre. The problem? That plastic — phenolic resin — is expensive to mould, leaves a rough finish that needs hours of hand-sanding, and gives off toxic, cancer-causing fumes during production. This project replaced it with a plant-based alternative called polyfurfuryl alcohol (PFA) that moulds faster, comes out smoother, and is completely non-toxic. Think of it like swapping a cheap paint that stinks up your house for one that dries faster, looks better, and is safe to breathe — except for airplane parts.

By the numbers

58%

Cost reduction over phenolic composites

34%

Reduction in moulding cycle time

70%

Reduction in manual finishing

70%

Reduction in filler use

Average component weight reduction

€1,824,585

EU contribution

Industry partners across 3 countries

Demonstrator parts produced

The business problem

What needed solving

Aircraft interior panels are made from phenolic resin composites that are expensive to produce due to long moulding cycles and hours of manual finishing. The phenolic material also emits toxic and carcinogenic substances during processing, creating serious workplace safety issues. Manufacturers need a drop-in replacement that is cheaper, lighter, and eliminates the health risks — without compromising fire safety performance.

The solution

What was built

The project developed and upscaled a polyfurfuryl alcohol (PFA) composite as a direct replacement for phenolic resin in aircraft interior parts. At least 2 demonstrator parts were produced to validate the material at production-relevant scale, with optimised formulations for processability, surface finish, and fire performance.

Audience

Who needs this

Aircraft interior panel manufacturers (Tier 1/2 suppliers)Composite resin and prepreg producers serving aerospaceAirline MRO providers handling cabin refurbishmentAircraft OEMs looking to reduce cabin weight and production costsWorkplace safety managers at composites manufacturing facilities

Business applications

Who can put this to work

Aerospace interiors manufacturing

mid-size

Target: Tier 1 or Tier 2 suppliers of cabin panels, overhead bins, sidewalls, and galley components

If you are an aircraft interiors supplier dealing with long moulding cycles and expensive manual finishing for phenolic composite parts — this project developed a PFA-based composite that delivers a 58% cost reduction over phenolics, a 34% shorter moulding cycle, and a 70% reduction in manual finishing time. The improved surface finish also cuts filler use by 70%, reducing average component weight by 4%.

Composite materials supply

SME

Target: Resin and prepreg manufacturers serving the aerospace sector

If you are a composites material supplier looking for a drop-in replacement for phenolic resins in fire-rated applications — this project upscaled a polyfurfuryl alcohol resin system that meets aircraft interior fire and mechanical standards while eliminating toxic and carcinogenic emissions during processing. It offers a direct route to differentiate your product line with a safer, lower-cost alternative.

Aircraft MRO and cabin refurbishment

enterprise

Target: Airlines and MRO providers handling cabin interior refits and repairs

If you are an MRO provider or airline looking to cut refurbishment costs for cabin interior panels — parts made with this PFA composite are 4% lighter on average and 58% cheaper than phenolic equivalents. The non-toxic processing also eliminates the need for hazardous-material handling during repair and replacement work, simplifying workshop safety compliance.

Frequently asked

Quick answers

How much cheaper are PFA composite parts compared to current phenolic parts?

The project reports a 58% cost reduction over phenolics, driven by a 34% reduction in moulding cycle time and a 70% reduction in manual finishing work. These are process-level savings that compound across production volumes.

Can this be produced at industrial scale, or is it still lab-grade?

The explicit goal of the project was to upscale from small-scale prototype equipment to production-ready manufacturing. At least 2 demonstrator parts were produced as part of the project. The Fast Track to Innovation (FTI) funding scheme is specifically designed for near-market technologies.

What is the IP situation — can I license this material?

The coordinator is Composites Evolution Limited, a UK-based SME specializing in bio-based composites. Licensing or supply arrangements would need to be discussed directly with them. Based on available project data, IP is likely held by the consortium partners.

Does PFA meet the fire safety regulations for aircraft interiors?

Yes. The project objective states that testing by prospective customers has shown PFA composites can meet aircraft interior standards for both mechanical and fire performance. The entire project was designed around meeting these strict fire and weight requirements.

How long would it take to integrate PFA composites into our production line?

PFA is designed as a direct substitute for phenolic resin, meaning existing glass fibre reinforcement and similar tooling can be used. The project focused on optimising processability and properties for production readiness. Based on available project data, integration timelines would depend on your certification pathway.

What about the weight savings — how significant are they?

The project reports an average component weight reduction of 4% compared to phenolic parts, achieved by reducing filler use by 70% thanks to PFA's superior surface finish. For airlines, even small weight reductions translate directly into fuel savings over an aircraft's lifetime.

Is there ongoing support or further development planned?

The project ended in October 2018. Composites Evolution Limited continues to operate as a composites manufacturer. For current product availability and technical support, direct contact with the coordinator would be needed.

Consortium

Who built it

This is a purely industrial consortium — all 5 partners are companies (3 of them SMEs), with zero universities or research institutes, spread across Germany, Italy, and the UK. That composition signals a technology that has already left the lab. The coordinator, Composites Evolution Limited, is a UK-based SME specializing in composite materials, which means the IP holder is a commercial entity focused on bringing products to market. With €1,824,585 in EU funding and 100% industry participation, this project was clearly designed to bridge the gap between proven technology and commercial-scale production.

COMPOSITES EVOLUTION LIMITEDCoordinator · UK
BERCELLA SRLparticipant · IT
NETCOMPOSITES LIMITEDthirdparty · UK
ELEMENT MATERIALS TECHNOLOGY HITCHIN LIMITEDthirdparty · UK

How to reach the team

Composites Evolution Limited (UK) — specialist composite materials SME and project coordinator

Order a report on this consortium See COMPOSITES EVOLUTION LIMITED profile →

Next steps

Talk to the team behind this work.

Want an introduction to the IntAir team to discuss licensing or supply of PFA composites for your production line? Contact SciTransfer for a facilitated connection.

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