Hutchinson’s Insulation and Ducting Solutions to Support Efficiency and Sustainability Goals of D328eco

Hutchinson, a recognised leader in advanced insulation and composite systems, has been chosen by Deutsche Aircraft to design, develop, and manufacture the Primary Insulation and Low-Pressure Air Ducting System for the next-generation D328eco regional turboprop. This selection places Hutchinson at the core of Deutsche Aircraft’s ambitions for improved aircraft efficiency, reduced emissions, and stronger sustainability performance.

Insulation and Air Ducting Capabilities

Hutchinson’s planned scope of work under its partnership for the D328eco^® programme centres on its extensive experience in thermal and airflow solutions for aerospace. Its offerings include insulated flexible ducts, tailored for Environmental Control Systems (ECS), which maintain cabin air temperature and reduce thermal losses. These ducts are engineered to meet fire, smoke, and toxicity standards while remaining lightweight, making them a suitable fit for modern aircraft.

Complementing the ducting systems are Hutchinson’s proprietary EPDM-based Bulatex^® foams. These materials offer thermal conductivity around 0.035 W/m·°C and operate within a broad temperature range from –50°C to +150°C. Manufactured at eco-compliant sites in France, the foams also contribute acoustic dampening while supporting energy efficiency goals.

In other transport sectors, such as electric vehicles, Hutchinson has successfully deployed twin-sheet thermoformed air ducts that reduce weight by over 50% and achieve notable noise attenuation. These multi-layer ducting systems demonstrate tangible benefits transferable to aviation applications, particularly where weight and noise control are key.

Track Record with Aircraft OEMs

Hutchinson’s capabilities are already proven in commercial aerospace. In the Airbus A350 freighter program, the company supplied composite structural rods that reduced component weight by approximately 20% without compromising structural performance. This accomplishment highlights Hutchinson’s ability to engineer load-bearing systems that support both efficiency and durability.

The company also contributes to nacelle insulation, radome production, and avionics support structures for various aircraft platforms. Its integrated systems—spanning vibration management, sealing, and thermal solutions—are applied throughout both commercial and business aviation segments.

Proven Approach to Performance and Sustainability

A key pillar of Hutchinson’s approach is its emphasis on lightweight construction paired with environmental responsibility. The D328eco^® benefits from Hutchinson’s deep background in composite materials, thermoplastics, and elastomers—all selected for their ability to reduce overall aircraft weight, limit energy use, and contribute to quieter cabins.

These objectives are supported by past implementations of low-pressure air ducts and thermal management components in both aerospace and e-mobility contexts. Examples include air handling systems in hydrogen fuel cell modules and insulation for electric vehicle battery environments. These cross-sector experiences reflect Hutchinson’s capacity to translate innovation into measurable operational improvements.

According to Nico Neumann, CEO of Deutsche Aircraft, “Partnering with Hutchinson is a natural fit for the D328eco programme. Their expertise in lightweight insulation and air ducting systems directly supports our mission to deliver a next-generation regional aircraft with improved cabin noise that is both efficient and environmentally responsible. This collaboration reinforces our commitment to innovation and sustainability in every aspect of the D328eco’s design.”

Nicolas Orance, Executive Vice President, Aerospace at Hutchinson, added, “We are honoured to collaborate with Deutsche Aircraft on this forward-looking programme. Our advanced insulation and air management technologies are designed to meet the highest standards of performance and sustainability, and we are proud to contribute to the D328eco’s success as a benchmark for the future of regional aviation.”

This strategic partnership highlights Hutchinson’s commitment to delivering innovative, sustainable solutions that enhance aircraft performance and environmental responsibility. With decades of experience in aerospace applications—including antivibration, sealing, fluid management, and lightweight materials—Hutchinson is uniquely positioned to support the D328eco programme with best-in-class technologies.

The D328eco, developed by Deutsche Aircraft, represents a new benchmark in regional aviation. Hutchinson’s ultra-lightweight insulation and air ducting systems will contribute significantly to the aircraft’s efficiency, reduced emissions, and operational competitiveness.

This collaboration, announced following the Paris Air Show, demonstrates the continued alignment between technical performance and sustainable design across the aerospace industry. For Hutchinson, it reinforces their leadership in systems that go beyond components—delivering integrated solutions that shape the aircraft of tomorrow.

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