Introduction

As part of the Airbus A380 development, COTESA was entrusted with designing and producing a ballistic-protected cockpit partition wall, a component that needed to combine structural integrity, ballistic resistance (B4 class), and aesthetic finish, all while maintaining strict aerospace weight constraints.

Challenge

COTESA was already producing lavatory components for Dasell when the need arose to develop a lightweight, visually finished, and bullet-resistant wall between the cockpit and either the forward lavatory or passenger cabin.

Core requirements included:

• Compliance with firing class B4 (per FAA AC 25.795-2 / JAR 25.795)
• Maximum surface weight of 6 kg/m²
• Simultaneous structural functionality, such as load absorption for items like a third pilot’s seat
• High visual finish with no risk of fragmentation toward the cockpit side

Additional integration challenges:

• Decompression flaps embedded within ballistic zones
• Drilled mounting holes requiring protective reinforcement
• Edge and connection area protection
• Ballistic overlay that supports cosmetic finishes without compromising safety

Solution

COTESA’s approach combined composite engineering with advanced military-grade protection techniques:

• Dual-construction wall system:
  • Cabin side: Lightweight CFRP (carbon fiber-reinforced polymer) sandwich
  • Cockpit side: Ballistic overlay made from aramid fabric layers, each coated in uncured rubber and vulcanized under pressure
• The two halves were bonded using a viscoplastic adhesive for mechanical reliability and stress dispersion
• Ballistic resistance was confirmed through extensive shooting tests, proving compliance under real-world stress scenarios

Additional engineered details:

• Custom cutting tools developed for clean, fray-free hole drilling in aramid layers
• Specialized protective covers for openings
• Steel profile reinforcements integrated around vulnerable edge and flap areas
• 3D molding capabilities allowed the ballistic component to match complex cabin geometries

Conclusion

COTESA delivered a pioneering solution that met or exceeded all ballistic, structural, and visual requirements—at a fraction of the weight of traditional systems.

• First ballistic cockpit wall solution implemented in commercial aviation
• Proven B4 ballistic protection at just 5.5 kg/m²
• Acquired industry-leading expertise in soft ballistic applications for aerospace