Boeing’s plastic plane cuts fuel use by 20%

Boeing’s Dreamliner features a carbon fibre composite fuselage

An increased use of carbon fibre composite materials over traditional aluminium has significantly reduced the weight of the aircraft and there is a reported 20% saving in fuel with no compromise on speed. As well as this, the carbon fibre composite fuselage requires far fewer parts compared with aluminium as there is less to bolt together. A one piece composite fuselage section saves a total 1,500 aluminium sheets and 40,000 aluminium fasteners.

The composite fuselage also means more humidity can be allowed in the cabin's air. In aluminium aircrafts the cabin air is kept dry to lessen the risk of corrosion. The 787's windows are also far larger than those in other aircraft.

"”Use of plastic carbon fibre composites is not new in aircraft and Formula 1 racing cars, but they have never been used on this scale before in a state of the art airliner like the 787,” said Peter Davis, director-general of the British Plastics Federation (BPF).

“Such a fuel efficient aircraft is good news for the environment and good news for the British companies, including BPF members who are supplying components.”

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