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SEKISUI Aerospace Thermoplastic Blocker Door

This project and technology is SEKISUI Aerospace funded for the development of a thermoplastic blocker door achieving improvements in these areas:

  • Cost
  • Fewer parts in final assembly
  • Environmental impact
  • Per-part cycle times
  • In-service part failure
  • Life-cycle cost
  • Weight
  • Acoustic treatment


Reasons for transitioning from metallic to composite (thermoplastic) specific to blocker door geometries include:

-Reduced weight
-Longer life (fatigue)
-Lower cost (geometry dependent and buy-to-fly ratio)
-Chemical resistance (Skydrol)

Materials and processes

Blocker doors are primary components of thrust reverser systems on modern commercial jets that redirect engine bypass air through cascades that move airflow out and forward, reversing the engine thrust direction during landing. SEKISUI Aerospace developed a one-piece, rib stiffened, thermoplastic blocker door using compression molding, redesigning a 787 blocker door to prove the concept.