How we actually shrank the Pacific

Making our client’s commercial aircrafts more fuel-efficient. All in a day’s work for us.

How we actually shrank the Pacific

The problem

Design light-weight wings and fuselage to make our client’s commercial aircrafts more fuel-efficient

Why is this a significant problem?

  • Conventional metal alloy wings and fuselage limit fuel-efficiency
  • Fuel consumed by the airplane accounts for 50 percent of the cost of flying
  • One transatlantic flight for a family of four creates more CO2 than what they generate domestically all year

Why is the problem challenging?

  • Large-scale use of light-weight advanced composites (instead of metal) in aircrafts is nascent
  • Engineers – designing aircraft bodies in metal for years – struggle with composite materials
  • Galvanic corrosion occurs when carbon composite materials come in contact with the aluminum body – both materials deteriorate

The solution

  • The team included both mechanical and software engineers to design the solution
  • Our software engineers built custom engineering applications to expedite the computer aided-design process
  • Using this, our mechanical engineers evaluated 5000+ designs, in advanced composites, in just 4 weeks
  • The prototype’s titanium fasteners eliminate corrosive contact between aluminum and composite material parts

The impact

  • Today, our client’s airplanes burn 25 percent less engine fuel
  • The fuselage is seamless. It has 80 percent less parts than a metallic fuselage i.e., 50,000+ parts off our client’s maintenance inventory
  • Each plane that burns less fuel is the eco-equivalent of 7000 cars off our roads all year