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Learjet’s Composite Airframe Bet

This computer-generated rendition of Bombardier's new Learjet Model 85 is amazingly close to the "real" thing. Bombardier
Gemini Sparkle

Key Takeaways:

  • The article details a problematic history for composite aircraft, citing examples like the Starship, Hawker 4000, and Boeing 787 that faced significant issues such as weight overruns, schedule delays, and structural challenges.
  • Learjet aims to avoid these past mistakes with its new composite Model 85 by employing experienced leadership (David Coleal) and setting realistic goals, specifically targeting an empty weight comparable to an aluminum jet rather than achieving significant weight savings.
  • The Learjet 85 utilizes conservative construction techniques, including improved hand layup prepreg carbon, oven curing without an autoclave, and a combination of bonding with extensive mechanical fastening to ensure structural integrity and reduce part count and manufacturing costs.
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When I first heard that Learjet would build its new Model 85 entirely from composite materials, I wondered what management there was thinking. So far there has not been an FAR Part 25 transport airplane built even mostly from composites. And the history of turbine-powered composite airplanes is sketchy at best.

The Starship, of course, remains the granddaddy of all composite airplane disasters. Back in the 1980s Beech spent somewhere between $800 million and $1 billion to build the factory, make the tooling and create the procedures to certify and manufacture the first turbine-powered all-composite airplane.

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