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Advanced Materials

​We have decades of expertise in developing cutting-edge material technologies designed to add strength and quality, yet reduce weight. Much of this pioneering work was initially developed for low-visibility and other military applications.

The Falcon V10 F was introduced in the 1980s and featured the first carbon wing to obtain FAR/JAR 125 qualification. Today, we continue to utilize advanced lightweight materials whenever they offer a significant performance – and economic - improvement.

For example, our engineers introduced a new carbon composite/cast titanium structure for the horizontal stabilizer on all Falcon models. This innovation requires one tenth of the number of parts and one third of the quantity of fasteners. And it is stronger, less expensive to produce and easier to maintain than a conventional aluminum airfoil.

Another excellent example of performance meeting economy is the precision cast cabin door adopted for the widebody Falcon 900 and 2000. This door requires less than half as many parts and fasteners as the traditional design.

The structure of our top-of-the-line Falcon 7X is almost 20% composite. It also features a composite carbon vertical stabilizer using an advanced resin transfer moulding (RTM) technique. This technique, which combines high-performance prepregs with direct processing using multiaxial reinforcements (a new non-crimp technology that provides strength and stiffness exactly where required), sharply reduces costs yet permits a high production rate.