Aviation composites make their way into football players’ gear

What do Boeing’s 787 Dreamliner and athletic gear have in common?

Boeing and Russell Brands are working to incorporate excess carbon fiber from the production of Boeing’s 787 into protective athletic gear.

The two companies will expand on an initial collaboration that uses 787 carbon fiber in Russell Athletic’s new CarbonTek football shoulder pad system.

Composite materials make up 50 percent of the 787’s primary structure, including the fuselage and wing.

Using aerospace-grade carbon fiber in shoulder pads gives a high strength-to-weight ratio and greater durability, Boeing said.

“We are thrilled to partner with Boeing and discover new ways to utilize carbon fiber used on the 787 to make innovative, game-changing products for the sports industry,” Robby Davis, Russell Athletic senior vice president and general manager, said in a statement. “It’s an exciting opportunity for both companies to leverage the value of carbon fiber used in high-performance gear while helping to meet environmental goals.”

Boeing markets surplus factory materials to meet its environmental and business goals.

And it sees opportunities to repurpose carbon fiber as it increases its use of composites in commercial airliners.

Boeing builds the 787 with carbon composites to increase fuel efficiency and improve passengers’ experience, Julie Felgar, managing director of Boeing Commercial Airplanes environmental strategy, said in a statement.

“Our collaboration with Russell Athletic is a fabulous opportunity to utilize the strength and lightweight characteristics of 787 carbon fiber to support athletes on the field,” she said.

Russell Athletic’s new shoulder pads have exoskeletons made of the carbon fiber, making them thinner and about 10 percent lighter than competitors’ shoulder pads, Boeing said.

The carbon fiber also increases range of motion and a secure fit for the athlete, it said.

A patent is pending.

Several collegiate players from Division I universities and three pro players with whom Russell Athletic has deals will be wearing the CarbonTek shoulder pads. The pro players are Pierre Garcon, Mark Ingram and Colt McCoy.

This story was originally published August 27, 2014 at 1:20 PM with the headline "Aviation composites make their way into football players’ gear."