A Decade After the Public Disclosure Professor Alma Thule FHEA, thule@mail.uk 03/09/24 Raptor Teaming Ltd. 1
B787 study was based on the earliest Boeing’s marketing (over)estimates of the Dreamliner’s weight reduction due to the implementation of composite materials in the full composite body fleet Instead of 20%, the actual weight reduction should have been used as being between 5-6% The published estimates showed the strong correlation against the flight regime compared to the manufacturing emissions Therefore the actual emissions reduction should be closer to one quarter of the presented value as shown in the AIM model 03/09/24 Raptor Teaming Ltd. 2
As communicated to our team during a two-day group meeting with Boeing’s material supplier in London over a decade ago, the accredited CFRP system could not satisfy the standard Mode II Fracture Toughness Test protocol for the composite material The CFRP system was modified by adding the thermoplastic interleaf layer in the middle of the specimen in order to artificially satisfy the Mode II FT test requirement and then inserted into the overall structure while manufacturing the composite components There is no evidence that the critical crack length would reach the interleaf layer which was added sporadically into the primary structure of the passenger aircraft 03/09/24 Raptor Teaming Ltd. 3
Timmis, AJ, A Hodzic (now Alma Thule), L Koh, M Bonner, C Soutis, AW Schäfer, and L Dray, “Environmental impact assessment of aviation emission reduction through the implementation of composite materials”, The International Journal of Life Cycle Assessment 20 (2), 233-243, 2015. “More action needed to clean up aviation emissions”, https ://www.imeche.org/news/news-article/more-action-needed-to-clean-up-aviation- emissions, Institution of Mechanical Engineers, 22 Dec 2014. USPTO - Patent with the US Army, US-11491771-B2, “Method of manufacturing a composite part”, 8 Nov 2022. USPTO initially registered by the US Army during the 45th President's term in office. 03/09/24 Raptor Teaming Ltd. 4
