Collins to Create Tougher, Lighter and Recyclable Thermoplastic Fins for F-16 Jets

The U.S. Air Force Research Laboratory (AFRL) selected Collins Aerospace to build an advanced high-impact resistant, F-16 ventral fin using thermoplastic welding technology, which will significantly reduce weight and cost of the current design.

Collins is investing approximately $100 million dollars over the next five years toward the advancement of its thermoplastic technology and plans to qualify and process thermoplastic materials for both military and commercial use. Under the three-year contract, the proposed work includes application of a specialized welding process, component design and prototype fabrication for the F-16 ventral fin. The effort will leverage best practices from similar programs including the recent composite-based F-16 horizontal stabilator.

Through automation processes on the manufacturing floor, the cost savings are expected to be upward of 30% where Collins can use thermoplastic composite materials. Thermoplastic resin is inherently tougher than thermoset resins typically used in production. Tougher materials reduce the overall weight allowing for thinner design and increased range of the payload. Thermoplastic materials have an indefinite shelf life, can be stored at room temperature, and can be reused or recycled. This eliminates the need for energy intensive cold storage required for thermoset raw materials.

The next step is to advance and mature the unique designs and manufacturing technologies specific to forming and thermally joining thermoplastics to create component assemblies. This work will be accomplished within the Riverside composites center.