Fabrication Methods

1. Carbon Fiber Reinforced Polymer (CFRP): The primary material used in the
Boeing 787 is CFRP. It consists of carbon fibers embedded in a polymer
matrix, typically epoxy. This material is known for its high strength-to-weight
ratio.
2. Resin Transfer Molding (RTM) & Resin Infusion: These processes involve
injecting resin into a mold containing the fiber layup under vacuum pressure.
This method is used for making complex shapes and ensures uniform resin
distribution, crucial for structural integrity.
3. Autoclave and Out-of-Autoclave Techniques: Components like the fuselage
and wings are cured in an autoclave, a pressurized oven that provides the heat
and pressure necessary for the resin to cure and harden. Out-of-autoclave
techniques are also employed for some parts, allowing for larger components
to be manufactured without size constraints of the autoclave.
4. Layered Construction: The composite materials are layered in specific
orientations to achieve desired strength and flexibility characteristics.
Advanced computer modeling aids in determining the optimal layup
configurations.

Material Science
1. Strength and Durability: CFRP exhibits high tensile strength and fatigue
resistance, essential for the structural integrity of an aircraft.
2. Lightweight: The use of composites significantly reduces the overall weight of
the aircraft, leading to improved fuel efficiency and lower emissions.
3. Corrosion Resistance: Unlike traditional metals, CFRP does not corrode,
reducing maintenance requirements and increasing the aircraft's lifespan.
4. Thermal Stability: Composites maintain their strength across a range of
temperatures, which is critical for aircraft that experience extreme
temperature variations.

Signal Transparency
1. Radio Frequency Transparency: One of the unique properties of composite
materials like CFRP is their transparency to radio frequencies. This is
particularly important for the aircraft's radar and communication systems.
2. Reduced Radar Signature: The composite materials can be designed to
absorb or reflect radar waves in a controlled manner, which can be
advantageous for military applications.
3. Challenges with Electrical Conductivity: Unlike metals, composites are not
inherently conductive. This necessitates the integration of conductive
materials or coatings to ensure proper grounding and protection against
lightning strikes.
4. Integration of Antenna Systems: The signal transparency of composites
allows for the seamless integration of antenna systems into the aircraft's
structure, reducing drag and improving aerodynamics.