Greener, safer and cheaper to run light aircraft
Light aircraft have come a long way from their beginnings over 100 years ago when they were first built from wood and canvas. This was followed by metallic aircraft and then by the introduction of composites. Despite three generations of improvement in materials, there have been no real systemic changes in aircraft construction. It’s a new systemic approach and the new use of composites that defines 4th generation aircraft. The EU-funded 4Gen Light Aircraft project developed a 4th generation light aircraft based on OneShot carbon fibre technology. OneShot, originally created for the construction of ocean racing yachts, is a new disruptive technology combining multiple procedures, components and materials in a one-step production process. France-based Elixir Aircraft(opens in new window) used this new technology to construct a ground-breaking two-seater light aircraft. Traditional mechanical assemblies such as screwing, riveting and glueing are eliminated. The wing, for example, is made without traditional ribs or spars.
New technology for a new generation
The company is the first in the world to design an entire wing (full span) entirely in OneShot. The fuselage, canopy arch and control surfaces (ailerons, flaps and vertical stabiliser) are also made in OneShot. This drastically reduces the need for assembly and is the main difference when compared to other composite aircraft. “The 4th generation of aircraft is made of OneShot carbon parts — that’s all — and it’s a game changer,” says Cyril Champenois co-founder of Elixir aircraft. “The Elixir, for example, comprises only 9 parts for its airframe, compared to thousands of pieces found in older generation aeroplanes,” he adds. These are made up of hundreds of parts, manufactured in moulds and then glued together. “In the case of OneShot, we take advantage of the composite to make everything in one operation, eliminating the hassle of assemblies,” Champenois notes. The result is a strong, yet extremely light construction with reduced operational costs and environmental impacts. Safety is also enhanced by the simplicity of the structure and performance improved by the reduced weight.
Out with the old
“A simpler design means there is less to go wrong and fewer failures, therefore greater safety, but also lower maintenance and costs,” comments Champenois. Operating costs are reduced to EUR 40/h (fuel + maintenance) and fuel consumption is very low at 11.7 l/h, compared to an average consumption of 38 l/h for previous generation planes. “Elixir Aircraft offers an aeroplane that meets the European Aviation Safety Agency Certification Standard CS-23(opens in new window) and is 50 % more fuel efficient than the vast majority of certified aircraft to date,” Champenois adds. 4Gen Light Aircraft’s goal is to modernise the fleet of ageing, previous generation training aircraft used by flight schools, which have become both economically and environmentally unsustainable. “We use innovations such as a safer structure, an anti-explosion fuel tank, an airframe parachute, and a unique safe-stalling behaviour system to protect lives where older generation aircraft cannot. Furthermore, replacing the global aircraft training fleet with 4th generation aircraft could save up to 547 000 tons of CO2 per year,” states Champenois. “After 50 years of flying heavy aircraft, using fuel-consuming and environmentally unfriendly engines, light aviation must lead the way in energy transition,” he concludes.
