Carbon fiber composites are favored by aerospace manufacturers for their strength, stiffness and durability, and are often produced from fossil fuels.
Of course, they can also be made from sustainable organic materials. Recently, Airbus created an experimental helicopter panel using a "bio-derived" fiber (bio-based carbon fiber composite), which was produced by capturing carbon dioxide from the atmosphere. The "bio-derived" fiber used by Airbus specialists is an alternative to traditional carbon composites that uses a "power to X" technology, which has been developed to industrialize bio-based carbon fibers.
For its part, Airbus said that the "X" stands for the end product, such as gas, heat or fuel.
They mentioned that "power to X" converts renewable energy into chemical products, including synthetic hydrocarbons, which can eventually be used to produce biofibers. The production process requires renewable carbon, either from non-fossil sources, such as biomass, or from carbon dioxide captured directly from the atmosphere.
In the pilot phase, Airbus researchers have demonstrated that it is possible to produce biofibers using a chemical (acrylonitrile) derived from atmospheric carbon dioxide.
Acrylonitrile is an intermediate that is typically made from crude oil, but the Airbus team used a sustainable alternative with the same chemical composition to produce a fiber with the same level of performance. Acrylonitrile is sourced from sustainable ISCC-certified non-fossil feedstocks (wood and food waste, recycled cooking oil, algae ......), as well as renewable ammonia and propylene.
The researchers used acrylonitrile-derived biofiber to manufacture a proof-of-concept nose panel for Airbus Helicopters' H145 Pioneer Laboratory. The panel was flight tested in May 2024 to demonstrate the airworthiness of this alternative fiber.
Tests have shown that the panels are as tough and strong as conventional aircraft components, and that the panel area is small enough to allow for fast, economical production.
Also, Airbus has conducted a full life-cycle analysis of the material: the production of sustainable acrylonitrile (as well as other bio-based chemicals and intermediates) produces much less CO2 than crude oil alternatives. However, their industrialization is still in its infancy. Scaling up so that the corresponding CO2 reductions are catalytic will require regulatory commitments and significant capital investment.
