A new chapter in decarbonising aerospace

By channelling investment into the most promising approaches (technically, environmentally and economically) the UK can advance an aerospace supply chain that promotes circularity and achieves net zero ambitions. In this article, NCC experts Tim Young,  Adrian Tayler, and Kyle Pender- discuss the opportunity to decarbonise aerospace by design and circular value chain.

Make aircraft more fuel efficient: that’s been one of the aerospace industry’s most direct paths to emission reduction for decades. And through advanced materials, we've achieved remarkable gains in fuel efficiency. But while lightweighting remains key, it's not enough on its own to stay ahead of tightening regulations, maintain competitiveness, or meet the UK Government’s ambitious net-zero targets which extend beyond the in-flight emissions.

The carrot and stick of regulation

Look at any major aerospace manufacturer's sustainability strategy, and you'll see the pressure building. New regulations like the Carbon Border Adjustment Mechanism (CBAM) are changing the rules of international trade, while stricter waste management requirements are forcing the aerospace supply chain to rethink their approach to materials and manufacturing.

Of course, lightweighting will always be important for fuel efficiency, but aerospace manufacturers also need to address the carbon footprint of their materials and processes. This shift comes at a crucial time as the industry gears up for the next generation of narrowbody aircraft. Put simply, it’s a golden opportunity to rethink how we build aircraft for a more sustainable future.

Resource efficiency: the new frontier

Did you know producing 1kg of carbon fibre can generate up to 35kg of CO₂? As a key lightweight composite material that the industry is increasingly reliant on for achieving fuel efficiency, that's a statistic we simply can’t ignore.

Which is why the NCC is fully committed to tackling this challenge head-on. How? By driving a state-of-the-art carbon fibre research line that will help create a compelling case for sustainable, UK-based carbon fibre production. The goal? To develop processes that are cost-competitive and significantly cleaner, which move away from the carbon-intensive fossil-based materials that dominate current production methods.

In the paper, Future strategies for decarbonisation of carbon fibre products: A roadmap to net zero 2050, NCC’s Kyle Pender suggests that even for complex production of material systems like carbon fibre, there are routes to develop that can achieve net zero. The transformative net zero strategy calls for a phased transition from bio-methane to e-methane to reduce reliance on natural gas, which must also be coupled with process efficiency, electrification, and alternative precursor fibres for a resilient transition.

We believe that even more reductions can be made by pursuing two other parallel paths: developing  truly net-zero materials – including bio-based precursors – and pioneering new waste-management strategies. By focusing on circular value cycles and developing investable solutions like continuous fibre recycling, we can maintain composite performance, yet dramatically reduce its environmental impact.

Building tomorrow's supply chain

The transformation we need goes beyond individual technologies – it requires rethinking the whole supply chain. And the UK has a unique opportunity to lead the charge by developing domestic carbon fibre manufacturing that has sustainability at its heart.

At the NCC, we're taking concrete steps toward this future. Our new modular research line will produce up to 5kg of 1k to 50k tow carbon fibre per week, allowing us to test, optimise and scale more sustainable production method. Our facility will be a testbed for bio-based precursors, advanced process control, and finding that sweet spot between cost, performance, and sustainability.

Coupled with catalysing new sustainable production methods of carbon fibre, the NCC is driving the development of new technologies and solutions for high-rate continuous carbon fibre recycling and the investment case for new circular supply chains

Looking Ahead

While making aircraft lighter is important, and decarbonisation of materials is a crucial step, it's just one piece of a much larger puzzle and the next five years will be crucial as industry grapples with these challenges and opportunities. And thanks to its track record in innovation and R&D, the UK has a real chance to lead this transformation. But success depends on Government, regulators, manufacturers, suppliers, and researchers working closely together.

Companies that put their weight behind sustainable materials, smarter manufacturing, and better recycling will be doing their bit for the planet, as well as positioning themselves at the cutting-edge of aerospace's next big chapter.

At the NCC, we’re taking action and working with partners to turn hurdles to sustainability into stepping stones for innovation. Getting to net-zero is a tough challenge but we know where we need to go – and there's no time like the present to get started.

About the authors

Tim Young is Chief Technologist for Advanced Materials at the NCC and Visiting Industrial Professor at the Bristol Composites Institute; he has dedicated over a decade towards the development and exploitation of advanced materials and technology solutions for novel applications.

Adrian Tayler is Head of Aerospace at the NCC. He leads the delivery of aerospace expertise across the entire product development lifecycle, from initial concept development and flying prototype manufacture to advanced digital manufacturing solutions and End-of-Life (EoL) recycling processes.

Kyle Pender is an Advanced Research Engineer in Sustainability at the NCC. Kyle has worked as researcher across a broad range of initiatives to bring cross-sectoral sustainable development to composite materials. He has expertise in developing composite recycling technologies, as well as design and manufacturing of composite structures using recycled materials. He specialises in lifecycle assessment and technoeconomic analysis of recycling technologies.