Smarter coatings for surfaces

As is often said, first impressions really count, so when passengers walk onto an aircraft, even if it is just subconsciously, the impression of the surfaces that surround them has an immediate impact. However, coatings and paints used in aircraft not only have to be pleasing to the eye, they also have to be tough to deal with the operational wear and tear and adhere to demanding industry standards.

Andreas Ossenkopf, director and head of aviation at Mankiewicz coatings, comments: “We have adapted to meet the changing needs of the sector over the years. We are the only paint manufacturer to produce qualified coatings for all three forms of aviation paintwork: exteriors, interiors and structural parts. The portfolio also covers a wide range; from standard products to sophisticated design effects.

“Two types of coating systems are available: water- and solvent-based paints. To best accommodate the production processes of painters, Mankiewicz coatings can be applied manually or by automated systems, although automated processes impose some exacting demands on the paint.”

Mankiewicz also produces coatings with added ‘smart’ functions and special properties added to the coating. For example, for hygiene-sensitive areas like lavatories or galleys, paints that contain antimicrobial inhibition qualities can be used. Once fully cured, they help to reduce bacterial growth without toxic side-effects. Also, they decrease disinfection costs and avoid odours caused by bacteria.

Ossenkopf says one of the main requirements demanded for interior coatings is achieving a uniformity of surfaces.

“When components are made by a variety of manufacturers, they coat them under differing conditions,” he explains. “Nevertheless, they must all look uniform in the aircraft. This means the coating systems have to deliver a consistent result even when carried out under different conditions and on different substrates – a challenge that we at Mankiewicz have successfully mastered with our products.

“Another design trend is to use paint to substitute other materials, for instance metals. In aircraft metals are unwanted, either because they are too heavy or too expensive. Further, electroplating becomes more and more restricted because of its significant toxicity and high complexity in serial production processes. In such cases the paint imitates the look and feel of metals, to satisfy the needs of the aviation industry. This way a high-quality appearance is achieved, without impacting the functionality of the structural parts.”

Quicker coating

In most cases, paints are applied by tier suppliers to interior structures and components, assembled and then fitted to the aircraft cabin. And with increasing demand and ramp up rates Mankiewicz has had to develop products that enable speedier production through automated or robotic application.

“It is necessary to produce ever increasing quantities of interior components, without having any extra time available,” states Ossenkopf. “The pressure on manufacturers is enormous to find faster, efficient solutions. Mankiewicz offers approved paint solutions that help producers speed up their processes, to increase capacities and to increase quality of surfaces in terms of uniformity at the same time. Our automation solutions of water or solvent based topcoats and fillers range from automated mixing to fully automated robot application.”

Automated application requires the coating to be applied right-first-time which means Mankiewicz’s products need to be adaptable and high performing.

“There is no human painter to undertake corrections, to carefully fill an uneven section of composite or apply a thicker coat of paint where the surface shows through. With automated processes the paint has to compensate for all such human interventions. It must be flexible, opaque and easily applied so that a machine can achieve perfect results.

“Mankiewicz interior paints were specifically developed and tested to meet all these requirements and our processing experts help customers optimise processes to save as much time as possible. Time that can be used to increase component production. Mankiewicz assures in the very early stages of development the robustness and specifics of an application, which is essential for a secure automated serial production process. Whether customers call for standard products or for special design effects, our experts find the optimum solution for every product and every process for the customer’s cost benefit.”

Design collaboration

Of course, making interior elements attractive involves design and colour choices from airlines, OEMs and other interior suppliers, so how does Mankiewicz work with everyone involved in putting an interior together?

“We cooperate with all market participants. This ranges from OEMs in new airframe fabrication to buyer furnished equipment (BFE) and seller furnished equipment (SFE) manufacturers and all tier suppliers of the supply chain. However, direct contact with the airlines and designers is essential. Mankiewicz is often involved from the start, when the airlines are selecting and defining the colour tones and effects for their cabins. Mankiewicz also has intensive exchanges with design firms and airlines in the trim and finish areas.

“Often in-house or airline designers compile a range of colours and effects that Mankiewicz supports with its extensive and qualified design-effect paint portfolio. We produce individually adjusted colour tones and tailor these precisely to the wishes of customers. This effectively gives each airline a tailor-made look, with which they are able to differentiate.”

Mankiewicz extends the same approach with aircraft refurbishment businesses and those involved in the MRO sector too, working closely together with all participants.

When it comes to safety, its products have to pass very strict fire, smoke and toxicity (FST) certifications.

“FST requirements and fire protection is naturally included in the property profiles of our paints to ensure that passengers have the chance to leave a burning aircraft in case of emergency. The paint must not be combustible, nor release toxic substances. This is especially difficult as most of the paints’ components like pigments, fillers and binders are easily inflammable.

“Mankiewicz’s ALEXIT-FST coatings reliably comply with fire protection regulations and even surpass the strict FST demands of the aviation industry. Next to FST values, heat release is a core factor in the aviation business – in this regard our interior products reach the lowest heat release values on the market.”

In recent years the introduction of composite materials such as CFRP, in order to make aircraft lighter, has had a big impact on paint manufacturers as these surfaces do not always lend themselves to producing a smooth surface.

“Composite materials and plastics should not result in any visible changes for passengers. The surfaces must still be flawless, flat and shiny. To achieve this, it is necessary to smooth irregularities out with fillers, to reveal the full glory of the coatings that give colour and effects. Without fillers the surface irregularities would otherwise show through to the final coat and would actually remain visible; an effect known as telegraphing.

“Mankiewicz tackles this challenge with a wide portfolio of fillers and primers that are perfectly suited to every material and the paints subsequently applied on them. This way the finished surface is completely even and the passengers are unable to see any difference between different materials.”

So what future developments does Ossenkopf foresee in aircraft interior paints and the systems that apply them?

“A new generation of water-based metallic paints brings even more shine to the aerospace industry. Our new Water Based Metallic Basecoat is already appealing to airlines and designers. They provide extremely brilliant colours and impressive optical depth that creates a 3D-effect. The shining effect of the pigments offers numerous design options and a wide range of sparkling metallic colours made for exciting interior finishes.”

www.mankiewicz.com/english/products-markets/aviation