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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 highlights a problematic history of composite aircraft development, with projects like the Starship and Boeing 787 often facing significant challenges such as missed weight targets, structural issues, and extensive delays.
  • Learjet aims to overcome these past failures for its new Model 85 by adopting a conservative, "belt-and-suspenders" approach, led by experienced composite manufacturing expert David Coleal.
  • Learjet's strategy includes realistic weight expectations (targeting aluminum-equivalent weight, not significant weight savings), utilizing advanced prepreg hand layup with oven curing, and combining bonding with mechanical fastening to reduce part count and ensure structural reliability.
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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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