Aerospace Insights: An Interview with Aaron Burdick

For over 35 years, James Cropper has been a trusted partner to the aerospace industry. AS9100-certified, our products are found in most commercial aircraft, delivering solutions throughout the supply chain. From surface finish that reduces paint requirements to adhesive carriers that enhance bond strength, our extensive range of nonwovens optimize processing, integrates fire protection, and provides some of the lightest-weight solutions available. As the aerospace industry advances with new demands from Advanced Air Mobility and a rising need for multifunctional, sustainable materials, we spoke with our Key Account Manager for Aerospace and Defense, Aaron Burdick. With over 25 years of experience, Aaron offers valuable insights on the industry’s direction, key trends, and how James Cropper’s materials are uniquely positioned to meet these challenges.
Q:
Welcome, Aaron. Please can you start by sharing a bit about your background and what brought you to James Cropper?

AB:
I began my aerospace career in composites as a shop mechanic performing a number of functions producing parts for commercial aircraft. I transitioned to a bond room lead responsible for the day to day fabrication of composite parts for military UAVs. From there I worked in research and development, producing proof of concept parts for new commercial composite airplanes. Over time I was promoted into management and I managed a series of different commercial and military programs. My experience allowed me to progress to program management and several senior roles. With the ability to work remotely I transitioned to sales selling honeycomb core for aerospace and most recently selling cork to support the space industry.

An opportunity presented itself at James Cropper to promote their nonwoven and metal coated products to the composites industry and it peaked my interest. I had experience using some of these types of materials in my past. Other material offerings that I was less familiar with have given me the opportunity to learn more of what the industry has to offer.
Q:
You have a lot of experience working in the aerospace sector, what is your perspective on the industry at the moment?
AB:
The aerospace industry is evolving rapidly, driven by a need for more efficient and sustainable solutions. Manufacturers are increasingly focussed on reducing weight to maximise fuel economy and using composite materials that enhance performance while also reducing environmental impact.

Advanced Air Mobility (AAM) and the design and manufacture of eVTOL aircraft is also an important consideration. A relatively new market but with high projected growth, there is a strong focus on lightweight materials to maximise fuel economy, pay load, and overall range. Stringent demands make composite materials a good fit, and they will play a central role in the delivery of these aircraft.
Q:
What do you think the future trends for the industry are?
AB:
There has been a growing interest in the use of thermoplastics over traditional thermosets in aerospace in recent years, primarily due to their recyclability and faster manufacturing times. This drive for increased production rates is also furthering developments in manufacturing, with out-of-autoclave (OOA) curing and processes such as AFP which facilitate increased efficiency and throughput.

There is also a drive to use both multifunctional and sustainable materials, both considered key enablers for future electric and low carbon emissions aircraft. The inherent lightweight nature of composites means that they are key to meeting the weight reduction requirements for reducing CO2 emissions and fuel consumption. However, there is a greater focus on the life cycle of these materials and reducing environmental impact to make their use more sustainable, with composition, production, waste and EOL all being taken into consideration.

In combination with sustainability, the multifunctionally of composite components, and in particular integral electrical conductivity, is also considered important for the next generation aircraft. The incorporation of both electrical and thermal conductivity is key to delivering LSP as well as preventing electromagnetic hazards which could impact safety and control of the aircraft.
Q:
What is James Cropper doing to support this next generation of aircraft development trends?
AB:
James Cropper supply a wide range of materials into the aerospace industry, our nonwovens are used extensively as adhesive carriers and as a basis for surfacing films, both applications that are as relevant to next generation aircraft as current. The advent of AAM and smaller eVTOL aircraft also introduces a demand for more aerodynamic shapes, as well as resistance to corrosion and fatigue, and in some cases, the use of composite battery enclosures. We offer a wide range of solutions for this market; including electrically conductive nonwovens for EMI shielding, abrasion resistance aramid veils to reduce blade wear, integrated fire protection and glass veils for galvanic corrosion protection.

From a manufacturing perspective our lightweight veils are also playing a part in aiding the adoption of the more automated, higher throughput production processes. They act as a stabilisation layer, supporting more fragile fabrics such as UD tapes, NCF and dry fabrics to ensure they maintain fibre orientation and structural integrity during handling, preventing distortion and misalignment, to enable efficient processing and part manufacture. In addition to stabilising the fabrics, the use of our thermoplastic veils also gives the added benefit of improved toughness in the finished part. The veil provides a consistent, uniformly distributed thermoplastic layer that significantly enhances interlaminar fracture toughness and structural durability.

In response to the drive for more environmentally conscious materials, we recently launched a range of sustainable nonwovens, manufactured from bio-sourced fibres and recycled carbon fibre reclaimed from the composite manufacturing process. These materials are designed for use in applications such as aircraft interiors, where they deliver enhanced surface finish and enable aerospace designers to close the loop without compromising on quality or performance.
Q:
You’ve mentioned a number of solutions for AAM and next generation aerocomposites, please could you elaborate a little on how James Cropper’s nonwovens contribute to more traditional aerospace applications as well?
AB:
Of course. Our nonwovens serve a variety of functions in aerospace. For instance, they are well established as a carrier substrate for adhesives and surfacing films; their uniform thickness ensures a consistent bond line and the open structure improves resin flow during manufacturing, increasing throughput while minimising defects.

Our materials can also enhance corrosion resistance in aircraft components and, when incorporated into the composite lay-up, lightweight thermoplastic veils improve the durability of aerocomposites by providing an integral, uniformly distributed thermoplastic layer to enhance interlaminar fracture toughness. In addition, our Tecnofire® fire protection materials offer essential safety features without compromising structural integrity.
Q:
You have over 25 years experience in the Aerospace and Defense, what excites you most about working in this sector?
AB:
I’m excited about the opportunity to collaborate with likeminded, innovative manufacturers who are pushing the boundaries of what’s possible in aerospace. At James Cropper we are focused on sustainability and offering light weight solutions. Our advanced materials align with industry trends and I’m eager to help our customers leverage our technologies to achieve their goals.

Discover more about our solutions for Aerospace.

Our portfolio of products are in use on most commercial aircraft, delivering surface finish solutions, improved processing, light weighting efficiency solutions, fire protection and more.