Today's aviation industry faces a major challenge—rising fuel costs. To overcome these challenges, Collins Aerospace is at the forefront, delivering advanced structural solutions to make aerospace products lighter, safer, stronger, and more cost-efficient . And just as we're committed to aerospace, we're identifying how thermoplastics can also improve products used in defense applications.

two robotic arms

Introduction of thermoplastic composites technology

Known for its higher impact resistance, unique processing possibilities, lightweight properties, and strength, thermoplastic composites are increasingly being used in the aerospace industry to replace various metallic and thermoset composite parts.  These materials are increasingly used in aerospace to replace metallic and thermoset parts. With thermoplastics, structural weight can be reduced by 20% to 50%, supporting improved performance and operational efficiency.

When it comes to manufacturing more complex parts, thermoplastics outshine the competition. Parts can be manufactured in minutes instead of hours, and in fact, customers can benefit by as much as an 80% reduction in manufacturing cycle time for the same part that’s even lighter.

Using a combination of materials, manufacturing processes, and unmatched expertise, integrated thermoplastic composites—like access doors, engine nacelles, flight control surfaces and interiors—are lighter in weight and more affordable. This is due to their unique welding properties which minimize and eliminate the need for fasteners. These  structures are also better suited for harsh environments.

Benefits of thermoplastic composites

Up to a 50% weight reduction in structural components compared to metallic solutions.

Parts manufactured in minutes instead of hours

80% reduction in manufacturing cycle time

Higher impact resistance compared to thermosets

Assembly by welding minimizes and can even eliminate the need for fasteners

Ability to repurpose at the end of their lifecycle

Fly lighter, use less fuel

Aircraft structures made with thermoplastic composites can reduce operating costs by improving fuel efficiency.

Airplane in flight

We’re advancing innovative materials and breakthrough technologies to create lighter weight, high-performance components – from the smallest brackets to even larger, complex fan cowls – to reduce the overall weight of an aircraft. And lighter means more fuel-efficient. With automated manufacturing and integrated thermoplastic composite structures, we can help you fly lighter – and meet evolving performance expectations along the way.

Acquisition of Dutch Thermoplastic Components

In November 2021, Collins Aerospace acquired Dutch Thermoplastic Components, now the Collins Almere site. As a result of this combination, we're shaping the future in advanced thermoplastic composites and accelerating the execution of our technology roadmap.

Computer rendering of a futuristic helicopter

Manufacturing complex aerostructure components

Collins Aerospace has been developing thermoplastic composite technology for more than 20 years. Now, with a primary customer collaboration center in the Netherlands and a facility in the U.S., we can bring lightweight aerospace parts to market with competitive pricing and shorter lead times. 

World map

Riverside, Calif. (AS9100)

  • Automated Tape Lay-up (max 2,000x1,500mm layup area)
  • Stamp forming press/thermoforming line (max tool size: 800mmx800mm)
  • Multi-axis induction welding
  • 8-tow Automated Fiber Placement (Q2 2022). Max. mold length 6m (static and rotation molds). Rotation horizontal molds max. weight 6t.
  • Hi temperature furnace (max. dimensions 10’ x 10’ x 12’)
  • Multi-axis NDI

Almere, Netherlands (AS9100 + NADCAP)

  • Tape slitter
  • 2D prepreg / tape cutter
  • Automated Tape Lay-up max. 6,000 x 1,500 mm layup area
  • Consolidation Press
  • Continuous Compression Molding
  • 2D machining center (consolidated panels)
  • Stamp forming presses/thermoforming lines up to a length of 1.5 meter  
  • Automated deburring stations
  • 3D machining center (consolidated parts)
  • CMM stations
  • Manual and automated NDI
  • Edge seal
  • Grit blast and paint
  • Tooling design and fabrication center 

All of our thermoplastic composite manufacturing is retained in-house, providing our customers with solutions that will meet shorter lead times, optimized weight and competitive pricing.

Our customer collaboration centers are equipped to support:

  • Modeling for thermoforming
  • Tape slitting
  • Automated tape laying
  • Consolidation by CCM and shuttle press
  • Stamp forming
  • Automated fiber placement
  • Assembly by welding
  • Continuous thermoforming
  • High-temperature ovens
  • Dimensional and NDI inspection
  • Edge seal, primer, painting
  • Test services
  • Internally qualified processes and material systems

At Collins Aerospace, structural components are built with the latest technologies and equipment. Each year, we invest millions of dollars to support aerospace composites and production automation. We also have extensive partnerships with well-known universities, associations and consortiums that specialize in thermoplastic composites, robotics and manufacturing.

We have the capacity to process both carbon and glass reinforced thermoplastic pre-peg systems (fabric and UD tape) using PPS, PEEK, PEI, PEKK and low melt PAEK resin. All of our materials are qualified to:

  • ABS5045
  • ABS5083
  • ABS5036
  • ABS502
  • BMS8-353
  • BMS8-399

Certifications include:

  • AS9100
  • NADCAP for CMM and ultrasonic inspection
  • AIPS 03-02-020 Manufacturing of monolithic parts with thermoplastic material
  • AIPS 03-07-002 Machining of FRP components
  • AITM 6-4005/4010 issue 10 Ultrasonic pulse-echo inspection of CFRP
  • BAC5914 Collation
  • BAC5023 Consolidation
  • BAC5348 Processing of reinforced thermoplastic laminates
  • BAC5691 Continuous Compression Moulding
  • BAC5980 Non-destructive inspection of aviation composite parts and structures

Quality, availability and minimal stock levels are important drivers for our business and customers. We pride ourselves on Just-in-Time and Vendor Managed Inventory to ensure part availability when you need it most.

Engineering Progress for Tomorrow

Collins Aerospace continues to innovate in structural design and manufacturing to support the evolving needs of the aerospace industry. Through investments in advanced materials like thermoplastic composites, we are improving performance, reducing part complexity, and supporting longer product life cycles.

Our latest thermoplastic induction welding technologies eliminate the need for thousands of bolts, screws, and fasteners—resulting in lighter-weight, fully integrated components.

Thermoplastics also simplify production by reducing cure time and removing the need for cold storage compared to thermoset materials.

With high resistance to impact and fatigue, these composites are engineered to deliver durability and long-term value across a range of aircraft platforms.

Partnerships

TPRC consortium

ACMA (American Composite Manufacturing Association)

NASA ACC (Advanced Composite Consortium)

University Leadership Initiative

ARM (Advanced Robotics for Manufacturing)

CompoWorld

TAPAS

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