What motivated you to join Albany International last year after a long career in aerospace at Textron?
I’ve only worked for two companies: the Royal Norwegian Air Force and Textron, where I held many different roles. I’ve always been passionate about aerospace and aircraft. During my last four years at Textron, I was on the industrial side, working with vehicles like golf carts, turf equipment, and airport tugs. Then, Albany approached me, and though I hadn’t planned to move, I visited their facility in Rochester, New Hampshire. There, I saw them working on the LEAP blades and fan cases for engines using innovative carbon fiber and resin composite technology. This was a game-changer for me, as I recognized it as the future of composites in aviation.
I was drawn to Albany not just because of their cutting-edge technology, but also due to their bold approach. Transitioning from textiles to aerospace is no small feat, especially when their first major aerospace project was the fan blade on the LEAP engine—one of the most complex components. The guts and innovation it took for Albany to enter the aerospace field this way resonated with me. I knew I wanted to be part of that journey.
Can you give us a layman's overview of the range of products Albany is designing and manufacturing for the commercial aerospace industry?
We use 3D weaving technology, which involves weaving carbon fiber forms that are near the shape of the final part. These forms are then placed into a tool, injected with resin, and come out almost as finished products. This process produces stronger, more durable parts because the fibers are woven in three dimensions, preventing the layers from separating like in traditional composites. Our blades, for example, stay with the engine throughout its life, eliminating the need for frequent maintenance and repair (MRO).
Compared to traditional composites, our technology offers greater strength in every dimension. This robustness not only extends the life cycle of the parts but also reduces the need for MRO. It’s a significant advantage, especially in the aerospace industry, where durability and reliability are crucial.
Where in your customer base do you view as having the most potential and appetite for your advanced aerospace products?
Our primary customer for the 3D woven parts is Safran, who we work with on the LEAP engine. We’ve also partnered with Safran and GE for their RISE engine, which is the next-generation engine in development. Additionally, we’re working with Airbus on their "Wing of Tomorrow" project, which envisions new aircraft designs in the next decade. While traditional aerospace companies remain our main clients, we’ve noticed a growing interest from eVTOL (electric vertical takeoff and landing) companies, particularly BETA, with whom we collaborated to design the lift blades.
At the Farnborough Airshow this year, our collaboration with BETA and our 3D woven technology caught a lot of attention. eVTOL companies are more open to adopting new technologies, and we’re excited to see where this growing relationship takes us.
What is the biggest challenge standing in the way of getting advanced materials into more aerospace applications?
Our biggest challenge is twofold: awareness and engineering traditions. We’re still relatively new to the aerospace industry, and many engineers are used to working with traditional composite or metal technologies. Shifting their mindset towards using 3D woven composites takes time. However, eVTOL companies are more receptive to innovative solutions, which is why we’ve made quicker progress with them.
Another challenge is the regulatory process. Approving a new technology for use in aircraft requires multiple layers of validation from authorities like EASA or the FAA. It’s a lengthy and rigorous process, especially when compared to traditional materials like titanium, which we can replace with our composites in certain parts of the aircraft.
Looking forward to the future of material science in aviation, which technological innovations are you most excited about implementing?
Materials science is where the future lies. Our strength in advanced materials gives us a significant edge, particularly as the aviation industry focuses on fuel efficiency and reducing aircraft weight. By using 3D woven technology, we can make planes lighter without sacrificing strength. Engineers are still learning to design with this technology, but the potential is immense.
If we can incorporate 3D woven parts into more sections of the aircraft, we’ll see significant weight reductions, which is crucial in aviation. This is particularly important with respect to the industry’s sustainability goals and the increasing focus on electric and other alternative propulsion aircraft. Our composites are not only lighter but also stronger, which, combined with the sustainability benefits, makes this technology even more attractive for the future.
