Process innovation in high-performance systems: From polymeric composites R&D to design and build of airplane showers

In the aerospace industry reducing aircraft weight is key because it increases flight performance and drives down operating costs. With fierce competition in the commercial aircraft industry, companies that focused primarily on exterior aircraft performance design issues are turning more attention to the design of aircraft interior. Simultaneously, there has been an increase in the number of new amenities offered to passengers especially in first class travel and executive jets. These new amenities present novel and challenging design parameters that include integration into existing aircraft systems without sacrificing flight performance. The objective of this study was to design a re-circulating shower system for an aircraft that weighs significantly less than pre-existing shower designs. This was accomplished by integrating processes from polymeric composite materials, water filtration, and project management. Carbon/epoxy laminates exposed to hygrothermal cycling conditions were evaluated and compared to model calculations. Novel materials and a variety of fabrication processes were developed to create new types of paper for honeycomb applications. Experiments were then performed on the properties and honeycomb processability of these new papers. Standard water quality tests were performed on samples taken from the re-circulating system to see if current regulatory standards were being met. These studies were executed and integrated with tools from project management to design a better shower system for commercial aircraft applications.