In the aviation industry that pursues ultimate safety, lightweight, and environmental protection, the selection of every material is crucial. Thermoplastic polyurethane elastomer (TPU), as a high-performance polymer material, is increasingly becoming a “secret weapon” in the hands of aircraft designers and manufacturers. Its presence is ubiquitous from cabin interiors to external components, providing critical support for the progress of modern aircraft.
1、 Get to know TPU: an extraordinary versatility
TPU is a high-performance elastic material that falls between rubber and plastic. It is highly favored due to its unique molecular structure, which consists of a hard crystalline phase and a soft amorphous phase. This “combination of rigidity and flexibility” characteristic allows it to combine various excellent properties:
Excellent mechanical performance: TPU has extremely high tensile strength, tear resistance, and wear resistance, and its wear resistance is even better than many traditional rubber materials, able to withstand frequent friction and physical impacts.
Wide range of hardness: By adjusting the formula, the hardness of TPU can vary between Shore A60 and Shore D80, from rubber like elastomers to hard plastic like products, providing great design flexibility.
Excellent weather resistance and chemical resistance: TPU can resist the erosion of oils, fats, many solvents, and ozone, while also having good UV resistance and high and low temperature resistance (usually maintaining performance at temperatures ranging from -40 ° C to+80 ° C, and even higher), and can adapt to complex and changing high-altitude environments.
High elasticity and shock absorption: TPU has excellent rebound performance, which can effectively absorb impact energy and provide good cushioning and protection.
Environmental protection and processability: As a thermoplastic material, TPU can be quickly processed and molded through injection molding, extrusion, blow molding and other processes, with a short production cycle and high efficiency. And the scraps can be recycled and reused, which meets the requirements of sustainable development.
Good transparency and modifiability: Some grades of TPU have high transparency, are easy to dye, and can meet different aesthetic design requirements.
2、 The specific application of TPU in the aviation industry
Based on the above characteristics, the application of TPU in the aviation field is constantly expanding, mainly covering the following aspects:
Cabin interior and seating system:
Seat protection cover and fabric: Aircraft seats need to withstand extremely high frequency of use and potential wear and tear. TPU film or coated fabric has excellent wear resistance, tear resistance, and stain resistance, making it easy to clean and disinfect. At the same time, it has a comfortable touch and can significantly extend the service life of the seat and enhance the passenger experience.
Soft packaging materials such as armrests and headrests: TPU foam material has good cushioning and comfort, and is used as a covering layer for armrests and headrests, providing passengers with soft support.
Carpet backing: Cabin carpets usually use TPU coating as backing, which plays a role in anti slip, sound insulation, shock absorption, and enhancing dimensional stability.
Pipeline system and seals:
Cable sheath: The wiring inside the aircraft is complex, and the cables need to be fully protected. The cable sheath made of TPU has the characteristics of flame retardancy (meeting strict aviation flame retardant standards such as FAR 25.853), wear resistance, torsion resistance, and lightweight, which can ensure the safe operation of critical electrical systems.
Tracheal and hydraulic pipes: For non extreme pressure conveying systems, TPU flexible pipes are selected due to their oil resistance, hydrolysis resistance, and good mechanical strength.
Safety and protective devices:
Emergency slides and life jackets: TPU coated high-strength fabric is a key material for manufacturing inflatable emergency slides and life jackets. Its excellent airtightness, high strength, and weather resistance ensure the absolute reliability of these life-saving devices at critical moments.
Component protective covers and coverings: TPU material protective covers can be used to protect precision components such as engine air intakes and airspeed tubes during aircraft parking or maintenance, resisting wind, rain, ultraviolet radiation, and external impact.
Other functional components:
Drone components: In the field of drones, TPU is more widely used. Due to its excellent impact resistance and lightweight characteristics, it is used to manufacture protective frames, landing gear, gimbal shock absorbers, and the entire fuselage shell of drones, effectively protecting internal precision electronic components from damage during drops and collisions.
3、 TPU brings core advantages to the aviation industry
Choosing TPU can bring tangible value to aircraft manufacturers and operators:
Lightweight and reduces fuel consumption: TPU has a relatively low density and can be lighter than many traditional metal or rubber components while providing equivalent protective performance. Every kilogram of weight reduction can save significant fuel costs and reduce carbon emissions throughout the entire lifecycle of the aircraft.
Improving safety and reliability: TPU’s flame-retardant, high-strength, wear-resistant and other characteristics directly meet the most stringent safety standards in the aviation industry. The consistency of its performance ensures the reliability of components in long-term use and extreme environments, safeguarding flight safety.
Extend service life and reduce maintenance costs: The excellent durability and fatigue resistance of TPU components mean they are less prone to wear, cracking, or aging, thereby reducing the frequency of replacement and repair and lowering the maintenance costs throughout the aircraft’s lifecycle.
Design freedom and functional integration: TPU is easy to process into complex shapes, allowing designers to achieve more innovative structures. It can also be combined with other materials such as fabrics and plastics through lamination, encapsulation, and other methods to create multifunctional composite components.
In line with environmental trends: TPU’s recyclability aligns with the global aviation industry’s transition towards a circular economy, helping manufacturers achieve their sustainable development goals.
Conclusion
In summary, TPU is no longer an ordinary industrial raw material. With its outstanding performance in comprehensive balance, it has successfully entered the “high-precision” field of the aviation industry. From improving passenger comfort to ensuring flight safety, from reducing operating costs to promoting green aviation, TPU is becoming an indispensable high-performance material in modern aerospace manufacturing due to its multifunctional role. With the continuous advancement of material technology, the application boundaries of TPU will continue to expand, providing more possibilities for innovative design of future aircraft.
Post time: Sep-03-2025