9 − 10 SEPTEMBER 2014 ICAO HQ, Montréal, Canada

Composite Aircraft Recycling

• The Coming Wave

• Why Recycle?

• The Technology Challenge

• Enabling Solutions Through Collaboration

Fuelling Aviation with Green Technology, ICAO HQ, Montreal, Canada, 9 and 10 September 2014

Copyright © 2014 Boeing. All rights reserved.

Airplane deliveries: 36,770 2014 - 2033

Market value: $5.2T 2014 - 2033

0

10,000

20,000

30,000

Regional jets 7%

Single- aisle 70%

Small wide-body

12%

Large wide-body

2%

Medium wide-body

9%

0

1,000

2,000

3,000

Regional jets 2%

Single- aisle 49%

Small wide-body

22%

Large wide-body

5%

Medium wide-body

22%

2,490

25,680

4,520 620 3,460

$100B

$2,560B

$1,140B

$240B

$1,160B

Copyright © 2014 Boeing. All rights reserved.

Units

36,770

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

2013 2033

5,410

Retained fleet

15,500

Replacement

42%

21,270

Growth

58%

42,180

20,910

Fuelling Aviation with Green Technology, ICAO HQ, Montreal, Canada, 9 and 10 September 2014

Carbon laminate

Carbon sandwich

Fiberglass

Aluminum

Aluminum/steel/titanium pylons

Composites

50%

Aluminum

20%

Titanium

15%

Steel

10%

Other

5%

787 Dreamliner Construction

Carbon laminate

Carbon sandwich

Fiberglass

Aluminum

Aluminum/steel/titanium pylons

Carbon laminate

Carbon sandwich

Fiberglass

Aluminum

Aluminum/steel/titanium pylons

Composites

50%

Aluminum

20%

Titanium

15%

Steel

10%

Other

5%

Composites

50%

Aluminum

20%

Titanium

15%

Steel

10%

Other

5%

787 Dreamliner Construction

Expanded use of composites to improve aviation’s efficiency

0

20000

40000

60000

80000

100000

120000

Car

bo

n F

ibe

r D

em

and

by

Mar

ket*

(

Me

tric

To

nn

es)

Aerospace

Consumer

Industrial

*Data from Composite Market Reports Presentation, Carbon Fiber 2012 Conference

Fuelling Aviation with Green Technology, ICAO HQ, Montreal, Canada, 9 and 10 September 2014

Improving Environmental Performance Through the Airplane Lifecycle

Copyright © 2013 Boeing. All rights reserved.

Innovative

Environmental

Solutions

Lifecycle Environmental Footprint Reduction

Materials and

Manufacturing

In Service

End Of Service

Fuelling Aviation with Green Technology, ICAO HQ, Montreal, Canada, 9 and 10 September 2014

Increasing Recycling Throughout Lifecycle

Recycled carbon fiber

Exploring Interior and non-structural applications

Global technology partnerships

Goal is end-of-service solution

Standards for aircraft recycling

Founding member of Aircraft Fleet Recycling Association

Elevate industry performance & increase commercial value for end-of-service

Recycling metals

Innovative program to recycle Titanium and aluminum from across supply chain

Reducing energy consumption by using recycled content on products

Carbon fiber drives lifecycle efficiency CFRP use in transport aircraft rapidly pays off in reduced energy consumption

Fuelling Aviation with Green Technology, ICAO HQ, Montreal, Canada, 9 and 10 September 2014

Rel

ativ

e Fo

ssil

Fuel

Use

Flight Distance ( arbitrary Units) Source: University of Sheffield

Fuelling Aviation with Green Technology, ICAO HQ, Montreal, Canada, 9 and 10 September 2014

Recycling carbon fiber is more energy efficient than manufacturing new carbon fiber

T. Suzuki and J. Takahashi, Proceedings of 9th Japan International SAMPE Symposium, (2005-11), pp.14-19.

Energy to recover carbon fiber is 1/10th that to make new fiber

Fuelling Aviation with Green Technology, ICAO HQ, Montreal, Canada, 9 and 10 September 2014

Shredding Cured CFRP

After removal of fines

Recovered Fibers

787 Test Barrel

F18 Empennage

Exploring processes for efficient recycling of Carbon Fiber Efficient size reduction and classification needed

Fiber Recovery

Value Added Materials End of Service

Contaminated Shred Challenge

Milled CF Compounds Broadgoods

As Shredded

Fuelling Aviation with Green Technology, ICAO HQ, Montreal, Canada, 9 and 10 September 2014

Cryotank Prototype Part Tooling (Boeing NASA)

Aircraft Seat Back (Boeing - AFRECAR)

Eco Demonstrator Wing Access Doors (Boeing)

Kayak Paddle (Werner)

Potential applications in aerospace and beyond

F1 Auto Parts (Boeing-Renault)

Automotive Seating (Boeing – Ford-AFRECAR)

Automotive Structure (MIT-RCF)

Aircraft Interior Components (Boeing)

Exploration

In Use

Body Armor (Russell Athletic)

12

Boeing collaborates to drive carbon fiber recyclability • Processing Technologies, Application Exploration

• Loop Closures, End of Life Challenges

• Large Scale End of Service Trials, Process Commercialization

• Additive Manufacturing with Recycled CF

• Commercial Scale CF Recycling, Automotive Markets

• Exlpore Loop Closure Markets

• 787 Eco Demonstrator Flight Hardware

• Develop Non- Aerospace Markets

• Explore Solar Powered Fiber Recovery with BR&T China and

East China University

& Suppliers

END

OF

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VIC

E SO

LUTI

ON

S