Commercial aircraft OEMs, and Tier 1 and Tier 2 suppliers are continually faced with cost-reduction and efficiency challenges, as well as a growing need for core materials to pass stringent FAA fire, smoke, toxicity and heat release requirements. With fuel accounting for up to 50% of an airline’s direct operating cost, design engineers look for solutions to make everything lighter without sacrificing mechanical properties. Honeycomb, polyethersulfone, polymethacrylimide, polyetherimide, polyurethane and end-grain balsa are some core materials to consider. Some may be light and cost-effective but do not pass FST/OSU criteria, while others may pass FST/OSU requirements but prove to be expensive and over-engineered for an application. With these challenges, an FST/OSU-compliant core material with high strength and toughness was developed for the aerospace industry.
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