A Review on Evolution of Aircraft Fuselage Materials: From Wood to Composites & Functionally Graded Materials

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This is an unedited manuscript accepted for publication and provided as an Article in Press for early access at the author’s request. The article will undergo copyediting, typesetting, and galley proof review before final publication. Please be aware that errors may be identified during production that could affect the content. All legal disclaimers of the journal apply.

Year : 2026 | Volume : 14 | 02 | Page :
    By

    A. Bala Yaswanth Sai Reddy,

  • S.N. Padhi,

  • P. Kasi Visweswara Rao,

  • Shaik. Nagoor Baba,

  1. M.Tech Student, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur District, Andhra Pradesh, India
  2. Professor, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur District, Andhra Pradesh, India
  3. Associate Professor, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur District, Andhra Pradesh, India
  4. M.Tech Student, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur District, Andhra Pradesh, India

Abstract

This article presents a comprehensive overview of the evolution of materials for construction of aircraft fuselages, with a focus on the expanding use of polymer composites and functionally graded materials (FGMs) in modern aerostructures. The baseline fuselage design is thought to be from wood, to be followed by metallic systems such as aluminum, titanium, and nickel alloys. All systems improved manufacturability, strength, and longevity, but there was a substantial revolution with the initial introduction of fiber-reinforced polymers (FRPs), and more specifically CFRPs, since they provided with substantial reductions in weight, as well as significant improvements in stiffness, corrosion resistance, and fatigue performance. All evolutionary improvements, previous and present, even hybrid laminates specifically designed to mitigate issues with brittleness, repairability, recyclability and susceptibility to impact, as well as redesigned resin systems and nanomodified polymers and thermoplastic polymers, have enhanced composite and multi-material fuselage designs. FGMs have also emerged, as a next generation class of materials that can offer gradual changes and variations in composition and performance properties in order to mitigate interfacial stresses, and enhance multi-functional performance under extreme aerodynamic environments in aerospace systems. The advances in additive manufacturing technologies have been significant, and the advance provides unprecedented practical implementation of polymer-based FGMs with complex topological structures. Together, multi-material systems provide a future pathway toward lighter, stronger, more damage tolerant, and sustainable fuselage designs for future aviation systems.

Keywords: Aircraft Fuselage Materials, Aluminum Alloys, Composite Materials, Functionally Graded Materials, Additive Manufacturing, Aerospace Structural Design.

How to cite this article:
A. Bala Yaswanth Sai Reddy, S.N. Padhi, P. Kasi Visweswara Rao, Shaik. Nagoor Baba. A Review on Evolution of Aircraft Fuselage Materials: From Wood to Composites & Functionally Graded Materials. Journal of Polymer & Composites. 2026; 14(02):-.
How to cite this URL:
A. Bala Yaswanth Sai Reddy, S.N. Padhi, P. Kasi Visweswara Rao, Shaik. Nagoor Baba. A Review on Evolution of Aircraft Fuselage Materials: From Wood to Composites & Functionally Graded Materials. Journal of Polymer & Composites. 2026; 14(02):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=239796


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Ahead of Print Subscription Review Article
Volume 14
02
Received 25/11/2025
Accepted 26/12/2025
Published 07/04/2026
Publication Time 133 Days
28

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