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07 Mar 2007  -  United States

Nordam pioneers composite window frames for Boeing 787

Hexcel Corp. report that Nordam has received approval from The Boeing Company to supply its new composite window frame for the 787 Dreamliner using HexMC® from HEXCEL. After eighteen months of detailed specification development, design configurations, and qualification and certification testing, the first composite window frame for a commercial airliner application has been produced. The initial ship sets have been delivered to Boeing’s fuselage manufacturing partners: Alenia, Kawaski Heavy Industries, Spirit Aerosystems and Vought Aircraft Industries.

“The Dreamliner is an innovative program for composites in airframe construction.” said Rick Armstrong, Nordam vice president of sales and marketing for military and air transport. “The technology is an important part of our industry’s future and to be on the leading edge of development is a great opportunity for us.”

To meet Boeing’s technical requirements for the window frame, Nordam engineers pioneered new manufacturing processes and partnered with HEXCEL to utilize HexMC®, an innovative product form of composite material which is derived from established aerospace industry high strength carbon fiber/epoxy tape. HexMC® offers low density, with good strength and stiffness properties.

“The 787 Dreamliner is a true step forward in aviation’s use of composite materials. It has involved a significant amount of development and engineering expertise,” said Al Miller, director of Advanced Technology for Boeing. “The window frame is a truly innovative product and has helped Boeing achieve performance targets for the aircraft.”

The 787’s window frame has a significant impact on two key characteristics of the Dreamliner. The new low density, high strength composite frame results in almost a 50 percent weight savings over a traditional aluminum frame. In addition, the frame offers superior damage tolerance.

“Boeing and Nordam have succeeded in integrating advanced materials into new primary flight structures,” said Gary Ball, vice president and general manager of Nordam Interiors and Structures. “Developing the 787 window frame was an engineering and manufacturing challenge that resulted in new technology, process improvements, and valuable experience for our team.” Nordam’s Interiors and Structures Division, located in Tulsa, Okla., will supply thousands of frames per year.

“We congratulate Nordam on its success in securing Boeing approval to manufacture the 787 window frame using Hexcel’s patented HexMC® technology” said Dave Tanonis, Hexcel’s VP Americas Sales & Marketing. “The HexMC® molding concept enables carbon fiber/epoxy parts to be manufactured that could not easily be made from composites, due to their geometry. There is great potential in the aerospace industry to optimize detail part weight using HexMC® and benefiting from a high strength, lower weight solution”.

Source : Hexcel