Because they are strong and light, composites are popular alternatives to metal in aircraft, but their downside is that they can delaminate due to stress or extended use. With support from the US Navy and US Air Force, Foster-Miller invented Z-Fiber®, a product that increases delamination resistance fivefold and makes parts 50 to 100 percent stronger.

Z-Fiber® is in use on F-18E/Fs as a replacement for a portion of metal fasteners and is saving 60 lb/aircraft.  It is expected to save more than $100 to $200 million in production costs over the life of the program. It is being evaluated by Boeing, Lockheed, Bell, GE, Northrop-Grumman, British Aerospace, Dassault and the German Airbus Group, among others, for incorporation in major aerospace components.

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