Did you know the latest fuel tanks for helicopters are made from fabric?

Did you know that the future of helicopter safety is woven from fabric? While this might sound impossible, cutting-edge fuel tanks made from woven textiles are revolutionising helicopter design across Europe – and it's a story that demonstrates how innovation, sustainability, and safety work together to create extraordinary solutions.

The science behind the innovation

Traditional fuel tanks in helicopters were made from metal – heavy, rigid, and vulnerable to catastrophic failure in crash scenarios. But European engineers had a different vision: what if fuel could be stored in something as flexible as fabric, yet as strong as armour?

Enter woven fuel tanks – sophisticated textile structures that are transforming helicopter technology. Made from specially engineered polyamide fibres, woven with precision and coated with advanced materials, they create containers that are lightweight, flexible, and incredibly tough.

The crash-resistant fabrics are typically constructed from polyamide (nylon) fibres that undergo a complex manufacturing process. The weaving patterns are optimised for maximum strength, while special coatings ensure complete fuel compatibility and prevent leakage.

What makes these tanks extraordinary is their ability to absorb impact energy during a crash. Unlike rigid metal tanks that can rupture, fabric tanks deform and absorb shock, significantly reducing the risk of fuel spillage and post-crash fires. 

The manufacturing process involves multiple layers of precisely woven fabric, each serving a specific purpose. The outer layers provide puncture resistance, while inner layers ensure fuel containment. Advanced coating technologies create barriers that prevent fuel permeation while maintaining the fabric's flexibility.

European leadership in sustainable aviation

This innovation also perfectly embodies Europe's commitment to sustainable aviation. The European aerospace industry is investing heavily in clean technologies, with programmes like Clean Sky 2 delivering breakthrough innovations that reduce emissions. Fabric fuel tanks are part of this sustainability mission.

Weight reduction is crucial for environmental performance. These woven tanks can reduce fuel system weight by up to 25% compared to traditional metal alternatives. In aviation, every kilogram saved translates to reduced fuel consumption and lower emissions throughout the aircraft's lifetime. When you multiply this across entire helicopter fleets, the environmental impact becomes substantial.
ASD member Safran is at the forefront of this technological revolution. The company has developed sophisticated manufacturing processes that combine traditional textile craftsmanship with cutting-edge aerospace engineering. Their fuel tanks undergo rigorous testing to ensure they can withstand extreme conditions while maintaining absolute fuel containment integrity.

As Europe works towards its Destination 2050 net-zero aviation goals, innovations like fabric fuel tanks demonstrate how creative engineering can simultaneously improve safety, reduce weight, and enhance sustainability. These tanks represent just one example of how the European aerospace industry is reimagining fundamental aircraft components.

Sources: Safran's contribution to the H160, Safran Group, 2022 (https://web.safran-group.com/safran-on-board/en/h160.html); Fuel tank - Safran Aerosystems - flexible / for aircraft / for helicopter, AeroExpo, 2024 (https://www.aeroexpo.online/prod/safran-aerosystems/product-169069-79825.html); TYPE CERTIFICATE DATA SHEET, EASA, 2024 (https://www.easa.europa.eu/fr/downloads/16512/en); Airbus Helicopters H175 - Wikipedia, 2007 (https://en.wikipedia.org/wiki/Airbus_Helicopters_H175); SAFETY INFORMATION NOTICE, Airbus, 2025 (https://www.airbus.com/sites/g/files/jlcbta136/files/2025-01/3061-s-00-rev1_2.pdf).