EcoDemonstrator

The ecoDemonstrator program followed the joint Rolls-Royce and Boeing Quiet Technology Demonstrator (QTD) program, which ran in 2001, 2005 and 2018 to develop a quieter engine using chevrons on the rear of the nacelle and exhaust nozzles, as well as an acoustically enhanced inlet liner. In 2001 an American Airlines Boeing 777-200ER with Rolls-Royce Trent 800 engines was used for the flight tests. Much testing was carried out at Glasgow Industrial Airport, Montana, the airport of Boeing's subsidiary, Montana Aviation Research Company (MARCO). The tests were successful, demonstrating better noise reduction than predicted and leading to redesign of wing leading edge de-icing holes to eliminate whistling, a modification which was immediately applied on the 777 production line. Once the QTD2 program began, this program started to be referred to as QTD1. The resulting design changes were demonstrated in the 2005 Quiet Technology Demonstrator Two (QTD2) program in which a new Boeing 777-300ER, fitted with General Electric GE90-115B engines, was used for a three-week trial, again mainly at Boeing's flight test centre at Glasgow Industrial Airport. As well as the modifications, the aircraft was equipped with extensive sound measurement equipment, and microphone arrays were laid out around the airfield. The chevrons have since been adopted on the Boeing 737 MAX series, 747-8 and 787 Dreamliner aircraft. Also tested on the QTD2 were streamlined toboggan fairings on the main landing gear to reduce noise. The NASA-designed inlet was installed in the right-hand nacelle of one of Boeing's two 737 MAX 7 prototypes, powered by CFM International LEAP 1B engines. The testing took place between July 27 and August 6. QTD aircraft summary ==ecoDemonstrator program==

The ecoDemonstrator program was formally launched in 2011, in partnership with American Airlines and the FAA. The first ecoDemonstrator aircraft, a Boeing 737-800, operated during 2012. Since then a different aircraft has been used each year, excepting 2013 and 2017 and a single aircraft from 2022 to 2024, with testing operations lasting from a few weeks to over six months. The testing is usually done in collaboration with many industry partners, including NASA, the FAA, airlines, makers of engines, equipment and software, and academic institutions. The results of the tests are rarely publicised, respecting the confidentiality of the industrial partners. As of 2024 the program has tested over 250 technologies, of which 28% have been implemented, 52% are still under development, and 20% "provided helpful learnings" and were abandoned. Participating aircraft 2012: Boeing 737-800 This was a new aircraft destined for American Airlines and in their livery. With this, the first ecoDemonstrator, Boeing tested laminar flow technology for winglets, improving fuel efficiency by 1.8 percent. This fed directly into the design of the winglets used on the subsequent 737 MAX series. The aircraft tested other technologies, including: • variable area fan nozzle to optimize engine efficiency • regenerative hydrogen fuel cell for aircraft electrical power • adaptive outer wing trailing edges for greater take-off lift and decreased drag in cruise • active engine vibration control • flightpath optimization for operational efficiency • carpet made from recycled materials • sustainable aviation fuel (SAF). 2014: Boeing 787-8 The fourth production 787, a Boeing test airframe, was employed as the second ecoDemonstrator. It conducted 35 projects including: • use of a 15% blend of SAF by both engines for nine flights • acoustic ceramic matrix composite nozzle for weight and noise reduction • aerodynamic and flight control improvements. • advanced wing coatings to reduce ice accumulation. • software applications and connectivity technologies that can improve flight planning, fuel-load optimization, in-flight routing, and landing. • touchscreen displays on the flight deck. • wireless sensors to reduce wiring, reduce weight and save fuel. • outer wing access doors made from recycled 787 carbon fibre. • development of the Airborne Spacing for Terminal Arrival Routes (ASTAR) system to reduce spacing between aircraft on approach to airports. At the end of the testing period the aircraft was, in conjunction with the Aircraft Fleet Recycling Association and the aircraft lessor Stifel, disassembled for recycling. Around 90% of materials were reused or recycled. • green diesel fuel testing. 2016: Embraer E170 The third E170 prototype first flew in 2002 and was retained by Embraer as a test and demonstration aircraft. It was the only non-Boeing aircraft so far to participate as an ecoDemonstrator. Testing projects included: • use of LIDAR to complement existing air data sensors • ice-phobic paint to reduce icing and insect debris buildup • new noise-reducing flaps • special sensors to investigate airflow and improve aerodynamics • use of 10% Brazil-produced bio-fuel and 90% standard kerosene. 2018: Boeing 777F FedEx supplied a newly delivered 777 freighter for use in the ecoDemonstrator program. After two months of conversion, it was used in the testing program for around three months before restoration to its freighter role. Technologies explored included: • smaller, lighter weight thrust reverser • Safran electrical power distribution system • use of 100% biofuel – the first commercial airliner to be entirely powered by SAF. The engines were not modified in any way • 3D printed titanium tail fin cap using waste material and reducing the weight • synthetic ILS using GPS giving increased reliability and potentially allowing reduced separation of aircraft on approach • wake riding, involving flying closely behind another aircraft to give a fuel efficiency increase of up to 10% • LIDAR clear-air turbulence detector • SOCAS – Surface Operations and Collision Avoidance System, merging radar and video images for obstacle detection 2019: Boeing 777-200 This airliner had served Air China since 2001 before Boeing purchased it to join the ecoDemonstrator program. During testing, the aircraft visited Frankfurt, Germany, as several experiments were sponsored by German organisations including the German Aerospace Center (DLR), Diehl Aerospace, and Fraport. Among the 50 projects trialled were: • recyclable cabin carpet tiles • moisture-absorbent toilet floor made from recycled carbon fibre • chromate-free primer for aluminium parts to reduce manufacturing health risks • sharing digital information between air traffic control (ATC), the flight deck and an airline's operations center to optimize routing efficiency and safety • a connected electronic flight bag (EFB) application to provide re-routing information • connected galleys, lavatories, and cabin temperature and humidity sensors • cameras for an outside view for passengers. The program included: • noise measurement with over 1400 sensors for internal and external measurements • noise reduction including Safran undercarriage modifications • SAF testing with blends of 30% to 50% • sanitisation methods for the COVID-19 pandemic. • digital text-based ATC routing communications. 2021: Boeing 737 MAX 9 This 5-month program was conducted with a new airframe originally destined for Corendon Dutch Airlines but was painted in a special Alaska Airlines livery with ecoDemonstrator stickers. • halon-free fire extinguishing (ground testing only) • noise reduction engine nacelles including testing at Glasgow Industrial Airport, Montana • cabin walls made from recycled material • 50% SAF blend 2022: Boeing 777-200ER The aircraft was originally delivered to Singapore Airlines in 2002, and flew most recently for Surinam Airways. It wears a livery celebrating the 10th anniversary of the ecoDemonstrator program. Boeing implied that this aircraft will operate as the ecoDemonstrator test aircraft until 2024. among which were: • the use of a 30% SAF blend • disinfection of water from sinks for reuse in toilet flushing • weight reduction through 3D printed parts • noise reduction techniques • vortex generators which retract during cruise • head-worn head-up display enhanced vision system • fire-fighting system that does not use Halon • environmentally-friendly galley cooler refrigerant. 2023 In April 2023, Boeing announced that the 777-200ER would be testing 19 technologies during the year, including: • cargo hold wall panels made from recycled and sustainable materials • fibre-optic fuel quantity sensors compatible with SAF • smart airport maps by Boeing subsidiary Jeppesen for active airport taxiing monitoring for EFBs • all flights to use SAF in the highest available blend Between June 25 and 29, 2023, the aircraft operated from London Stansted Airport, performing flights over The Netherlands, Belgium, Germany and the Czech Republic, subsequently returning to its base at Seattle. no announcement had been made about the purpose of these flights. In December 2023, in cooperation with Nav Canada, the aircraft taxied from stand to runway at Vancouver International Airport using only digital communications via the EFB, with no voice contact with ATC. 2024 In May 2024, Boeing announced that the aircraft would be flying its program with a 30/70 mix of SAF and conventional fuel, starting later the same month. Among the 36 technologies to be tested would be: • cabin seat sensors to detect if a passenger leaves their seat during taxiing, takeoff and landing, touchless lavatory and more efficient galleys to increase efficiency and reduce food waste • single-engine taxiing and digital taxi clearances • steeper, continuous landing approaches for noise, fuel and emissions reduction • recyclable, lighter and more durable cabin flooring and ceiling panels • improved cabin insulation and bulkhead and galley acoustic panels. • OLED display screens integrated into cabin structure. Also tested were enhancements of the Jeppesen EFB which included in-flight fuel saving recommendations and prediction of taxi times using historical and real-time data. In September 2024, Boeing announced that during this round of testing it had performed 85 ground and 15 flight testing hours, testing 10 technologies, and highlighting the fuel and noise reduction benefits of modified approaches, some of which had already been adopted by the ICAO. On September 9, the aircraft flew from Seattle to Victorville, California. ecoDemonstrator aircraft summary All aircraft apart from the 2022 777 had ecoDemonstrator stickers applied to the fuselage or engine nacelles, at least one retaining them for some time after its participation in the program ended. ==ecoDemonstrator Explorer program==

In April 2023 Boeing announced a new program, ecoDemonstrator Explorer, using "platforms that will focus on short-term testing of a specific technology"'. The test flights will use the highest available blends of SAF in the process. Boeing expects that the fuel burn could be reduced by up to 10%. and returned direct to Seattle (Everett) on June 16. The Civil Aviation Authority of Singapore (CAAS) stated that this was part of a three-year programme. Boeing's chief pilot for product development stated that the TBO system, using technologies already in use aboard many modern airliners, allows pilots and air traffic controllers to make trial route change requests to see the cascading effects of the change on their, and other aircraft's flights, all the way through to airport gate availability, to see if they are likely to be approved. Second project On October 12, 2023, Boeing announced a second ecoDemonstrator Explorer project. It evaluated the environmental characteristics of SAF using a new 737 MAX 10 destined for United Airlines. Registered N27602, it made its first flight on September 14, 2023, and wore a special livery with "ecoDemonstrator EXPLORER" titles and "The Future is SAF" markings on the nacelles. It flew running on SAF from one fuel tank, alternating with conventional fuel from another tank. The emissions from the CFM International LEAP 1B engines were sampled by the NASA Douglas DC-8 Airborne Science Lab, registered N817NA, which flew behind the test aircraft. The characteristics of contrails produced were evaluated. Also collaborating on the project are the FAA, GE Aerospace, and the DLR. Test flights started on October 12, 2023, based at Everett Paine Field. 11 flights were performed, 8 over Montana and three over the Pacific off the coast of Oregon, at constant altitudes ranging from to . The average duration of each flight was around five hours, generally flying an extended racetrack pattern. At the end of the final test flight on November 1, the Explorer aircraft returned to Everett while the DC-8 flew back to Plant 42, Palmdale, California. NASA stated that the test results will be released to the public. Third project On December 10 2025, Boeing announced that it had completed the third ecoDemonstrator Explorer project, using a 737 MAX 8 of United Airlines who also provided the pilots. The project tested Internet Protocol Suite (IPS) communications, designed to replace existing systems to offer a network with improved safety and strengthened security, using satellite links between the aircraft, air traffic control, and airline operation centers. IPS is a component of Trajectory Based Operations (TBO) as trialled in the first ecoDemonstrator Explorer project. Collaborating organisations on the project were Collins Aerospace, Embry-Riddle Aeronautical University, The European Space Agency (ESA), the US FAA, Honeywell, SITA, Thales, Viasat, and NASA. The aircraft made its first test flight on October 29, and a total of nine flights were performed out of Houston until November 2. It then flew via Bangor, Maine, to Edinburgh, Scotland from where it made a test flight on November 6 over The Netherlands and Germany, returning to Houston, again via Bangor, on the 7th. After a week of preparations, the aircraft returned to airline service on November 14. ecoDemonstrator Explorer aircraft summary ==Footnotes==