Case Studies

Weight of business jet components reduced by 50% with ZOTEK F high-performance foam

With business jet travel under constant scrutiny, improving the sustainability of private aviation is an urgent priority for aircraft manufacturers.

Making smarter material choices which reduce the weight of an aircraft is essential to meeting this objective, and ZOTEK F high-performance foam is unlocking significant weight reductions, making a considerable impact on total fuel burn.

Thermoforming expert Plastika Balumag (Hochdorf, Switzerland) produces parts for a wide range of aviation applications, including window blinds, back coverings for seats, instrument panel coverings and other critical components. The most innovative example is a formed, self-insulating air duct assembly, which optimises air circulation through the on-board ventilation system. Conventionally, ventilation circulation systems are comprised of both rigid ducts, derived from heavier polycarbonate materials, and separate insulation products, which add further weight.

Manufactured using naturally inert polymer materials, ZOTEK F also boasts exceptional safety credentials. With outstanding fire, smoke and toxicity properties, ZOTEK F was selected as the preferred material for Plastika Balumag’s air ducts.

Also resistant to UV light, which is far more intense at high altitude, ZOTEK F is a material of choice across several other critical applications throughout the aircraft such as in interior finishes and wall panels.

ZOTEK F OSU XR is an extra-rigid closed cell crosslinked foam with structural and semi-structural capabilities: It is used extensively by leading aircraft manufacturers globally for window seals, soft-touch trim, close-outs, insulation, carpet underlay and environmental control systems. For Plastika Balumag, ZOTEK F OSU XR was the only lightweight alternative that met all the criteria for the application, while adhering to stringent aviation certification requirements.


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