The UK punches above its weight

Aerospace Technology Institute (ATI) strategy manager, Will McClintock looks at how the organisation is developing a roadmap for UK aircraft interiors.

Overall, aircraft interiors represent between 3% and 10% of an aircraft’s value, with a global market valued at $19 billion in 2019 and a 3.3% growth rate to 2040. Seat and in-flight entertainment (IFE) systems represent the most valuable opportunities by revenue. Connectivity was growing fastest, with a 7% 10-year CAGR. These projections have clearly changed somewhat in recent months, which I will discuss later.

The UK supplies approximately 7% of the world’s cabin products, including over 30% of all aircraft seats. All in, the ATI estimates there are over 250 aircraft interiors suppliers in the UK with a combined turnover exceeding £2 billion, supporting more than 6,000 jobs. The UK’s thriving industry is built on our academic pedigree, advanced manufacturing capabilities across multiple high-value engineering sectors, unrivalled concentration of industrial design organisations and the prevalence of airline and Tier 1 customers. Public resources – through the ATI, UK Research & Innovation and others – can also play a critical role in providing funding for research, technology development and growth. However, our analysis of the market has shown that these valuable system ingredients are often fragmented, reducing the potential competitiveness gains through investment and collaboration. Our ambition is to be the keystone to bind together this network and accelerate technology and innovation.

Aviation has ground to a halt in recent months. The recovery profile ultimately depends on the effectiveness of government policy and consumer behaviour changes as a result of the pandemic. This has affected the entire aerospace supply chain, cutting production by at least 30%. The aircraft interiors business saw a far deeper decline as airlines terminated non-essential spend. ‘Biosafety’ products for the aircraft cabin are being explored as a means to help restore demand, but whether they provide value and additional benefit remains to be seen. The issue may well be resolved more pragmatically by measures unrelated to aircraft cabin systems.

The world’s focus has changed in the last six months, and we expect some trends to be accelerated – such as the moves to improve the sustainability of aviation and ambitions for large zero-emission jets. This will also be a big opportunity to exploit a step change in aircraft structures and systems technology, such as lightweight integrated composite components. Fleet consolidation, particularly in the widebody market, is more pronounced as airlines are forced to take a hard look at operating economics and adjusting to evolving demand levels. Energy efficiency and light weighting will drive new products throughout the aircraft, including the cabin, with much opportunity in galleys, IFE, cabin air and seating. Airlines and interiors suppliers can start making gains in these areas well before new ultra-low emission aircraft enter the market. Ultra-long-haul travel was in growing demand before the pandemic, stimulating new cabin solutions to increase comfort and reduce stress. However, given the high fuel burn per passenger kilometre and bio-safety perceptions, the customers of ‘new normal’ may not buy into it.

Ripe for innovation

The aircraft interior market has evolved progressively, driven primarily by cost and delivery demands. Airlines seek differentiation and technology has filtered in, driving some technological progress, but nothing like what is possible. The breakneck progress in materials, digital, telecoms and other technology areas combined with the reinvigorated drive to reduce the environmental impact of aviation means the cabin interior is ripe for innovation.

Airlines have historically prioritised low cost and product/design innovation that directly impacts customer experience, which has not incentivised major light weighting innovations, sustainable materials or low energy systems. R&D spend for interiors suppliers is typically 4.5% of turnover. Although high, the vast majority is absorbed by product development and certification costs, with little left for new technology research and exploitation. This drives standardisation and makes true differentiation very expensive for airlines. There is limited financial resource or impetus to invest in higher-risk product and manufacturing technology, despite the potential to deliver long-term operational cost benefits. Thankfully, the tide is turning on this as airlines come under increasing customer pressure to reduce emissions.

Sales cycles are driven by new aircraft deliveries to airlines and refurbishments of older aircraft. Other aircraft systems must rely on new aircraft developments. This results in many more opportunities to bring new cabin products to market. Aircraft interiors present a fantastic opportunity to overcome aerospace quality challenges and pull new aerospace technology through to market, and enable and accelerate big step changes in technology throughout the aircraft. However, there are currently hurdles in creating the breathing space for suppliers to be able to do so.

Enabling lightweight structures

The UK is well placed in composite structures and additive manufacturing technologies. Composite technologies have long been an important material to the interiors sector, yet advances in thermoplastic composites and new sustainable materials could be exploited with improved production processes and recyclability. The ATI has also looked at specific opportunities through amorphous metal alloys and architectured 3D materials, which could be exploited to create multi-functional and substantially lighter metallic structures. Strong 3D printed plastics and transparencies as well as future sustainable fabrics are also areas of UK strength that could benefit future cabins.

Virtual certification enabled by smarter testing, data analytics and new design software will be essential to reduce development costs and bring revolutionary new products to market. Globally competitive manufacturing will require further automation and agile manufacturing enabled by digital thread, sensing, data analytics through AI, use of the cloud, and the integrated supply chain. Investment in these technologies will allow the UK to provide more capacity, whilst being able to deliver unprecedented levels of product quality and variety.

Driving UK prospects

Through ATI funding and plugging into our ecosystem, UK interiors companies can break the cycle by accessing new collaborative opportunities and leverage grants for innovation investment. Through this we aim to promote UK competitiveness and productivity, and unlock the business case for sustainable technologies to meet the UK’s net-zero commitment. We will support suppliers to deliver cost-competitive lightweight and recyclable composites seating structures, radical innovations in sustainable fabrics, galleys that use a fraction of the power and recycle waste heat, and not to mention internet connectivity that is affordable and reliable. Our recent INSIGHT paper - The UK Cabin Opportunity – sets out the beginning of a UK aircraft interior technology strategy, and we are actively working with industry to create clear technology roadmaps with the aim of accelerating the ambition of UK aircraft interiors to meet those goals. On 14th October we are hosting a one-day virtual event where industry leaders will present a vision for the future of interiors, and where we will build on our technology strategy through interactive breakouts and panels that challenge the UK sector and guides ATI funding.

Details on the 14th October event, and downloads of INSIGHT papers on cabin interiors, additive manufacturing, composites and digital transformation can be found on the ATI web site.

www.ati.org.uk