As global attention turns toward reducing pressure on our shared environment and making smaller footprints in the world, aerospace manufacturing is faced with a unique challenge: to continue creating the amazing machines we always have, but to do so with sustainable aviation practices. Advances in technology are paving the way for cleaner, more efficient aviation.
Sustainable Aviation: Cutting-Edge Technologies for Green Aviation
Fuels (SAFs)
One of the most promising advancements in green aviation is the development of sustainable aviation fuels (SAFs). These fuels are designed to replace traditional fossil-based jet fuel. Unlike conventional jet fuel, which is derived from petroleum, SAFs are produced from renewable sources, such as agricultural waste, algae, or even captured carbon dioxide. The result is a fuel that can potentially reduce lifecycle greenhouse gas emissions by up to 80%.
SAFs are largely compatible with existing aircraft engines and fueling infrastructure, so they are a very practical, short-term solution for changing things quickly for the better. Thankfully, the modifications needed to get current fleets running on SAFs is fairly minimal; but production and scalability of SAFs remain a challenge. Current manufacturing processes for the fuels themselves are resource-intensive.
The investment is worth it, however, as, in addition to reducing emissions, SAFs also offer the potential for a more circular economy in aviation. For example, biofuels derived from used cooking oil or agricultural residues would not only reduce reliance on fossil fuels for an airline but also prevent waste from entering landfills.
Electric Propulsion Systems
Electric propulsion is another cutting-edge technology that may transform the industry in the near future. By replacing traditional combustion engines with electric motors, aerospace manufacturing could potentially eliminate direct carbon emissions entirely. Fully electric commercial flights are still in the developmental phase, of course, but smaller electric aircraft are already being used for short-haul routes and pilot training.
The shift to electric propulsion involves rethinking aircraft design, though. Electric motors are lighter and more compact than conventional jet engines, so that does allow for greater flexibility in aircraft configurations. They’re also quieter. The challenge with electric aviation lies in energy storage.
Current battery technology is improving rapidly, but it is not yet capable of supporting long-haul flights, and fires – though rare – are still a concern because of their catastrophic nature when they do happen. Researchers are currently exploring advanced battery chemistries that have the potential to increase energy density and extend flight range as well as provide a safer mix.
Hydrogen-Powered Solutions
Hydrogen power could be transformative in achieving zero-emission aviation. Hydrogen, when used as a fuel, produces only water vapor as a byproduct. That makes it an ideal energy source for reducing greenhouse gas emissions. At the moment, there are primary approaches to using hydrogen: hydrogen combustion and hydrogen fuel cells.
In combustion, the fuel is burned in a modified jet engine in a manner similar to the way traditional fossil fuels are currently burned. The main difference is simply that hydrogen combustion does not produce CO2 emissions. While this technology is still in its early stages, several aerospace manufacturers are actively developing hydrogen-powered engines with the goal of commercializing the technology within the next decade. Hydrogen fuel cells, on the other hand, generate electricity by inducing a chemical reaction between hydrogen and oxygen. This reaction then powers electric motors. This approach is particularly attractive for smaller, regional aircraft. It’s highly efficient and a quiet energy source.
The primary challenge with hydrogen fuel cells is storage and transport. Transporting hydrogen efficiently and safely requires some advanced infrastructure because it is both low-density and high-volume nature. The adoption of hydrogen-powered aviation for the moment depends on whether we’re able to develop the larger overall hydrogen ecosystem.
Aerospace Manufacturing of Lightweight and Fuel-Efficient Aircraft
New materials have the potential to make aircraft lighter and more fuel-efficient, and since the weight of an aircraft directly impacts the amount of fuel it uses, reducing weight can make a big difference in emissions. Advanced composites like carbon fiber reinforced polymers (CFRP) are some of the most promising solutions here. These CFRP materials are not only lighter than traditional metals but also stronger and longer-lasting. With this combination of properties, you can design and produce thinner and more aerodynamic components without sacrificing structural integrity.
In addition to composites, researchers are exploring the use of nanomaterials and smart materials. Nanomaterials have exceptional strength-to-weight ratios, while smart materials, on the other hand, have the ability to adapt to environmental changes in temperature or pressure. And the production of these kinds of advanced materials is also becoming more sustainable. Innovations like additive manufacturing (3D printing) reduce material waste and make it possible to create complex, lightweight structures that were previously easy to dream but impossible to produce.
Artificial Intelligence
By analyzing vast amounts of data, AI algorithms optimize flight operations, enhance maintenance procedures, and improve fuel efficiency, all of which contribute to reducing the environmental impact of a flight. But that’s not all. AI in manufacturing allows for faster, more efficient designs, AI testing to work through problems quickly and efficiently, and better communication among all players along the manufacturing and supply chain.
AI is also revolutionizing aircraft maintenance through predictive analytics. Because AI can monitor the performance of aircraft systems in real-time, it can identify issues even before they truly become issues. And with all this data at your fingertips and powerful AI tools to analyze it, as a manufacturer, you can pull real-world insights into design and production much faster and more efficiently.
The future is green, and we’re ready to help you get there. Contact SAAB RDS, your sustainable technology partner, today and let’s get started.