Boeing NSA and the brilliance of the MC-21 fuselage.So in its latest communications Boeing seems to be hinting on a new single aisle design as their next airplane. Boeing is facing a tough challenge against a competitor that can offer further developments with similar capabilities based on existing designs and production facilities. It needs to have significant advantages in other areas in order to be able the compensate for the additional R&D and production ramp up costs.
In which areas would Boeing be able to be to create an advantage (some temporarily others structurally):
1. Production efficiency.
2. Lighter weight (from materials/technology and range reset.
3. Better fuselage design with faster boarding or better medium range comfort.
4. Length/capacity better adjust to market demand.
5. More room for high by pass ratio engines.
6. More capability.
1. Production efficiency.Sure, A320 production is very efficient with years of experience and huge scale production. On the other hand a new design can have production efficiency built into the design that a few decades old design simply can’t match in all areas. At ramp up Airbus would have the advantage, but once ramped up that would tilt towards Boeing.
2. Lighter weight (from materials/technology and range reset).The A320 series have grown overly capable for most of the missions. Sure, that means that it is very flexible as well, but it also means that ten thousands of planes flying at each moment in time, are heavier than necessary. Furthermore, a new design can make use of new technologies, like composite wings/wingbox, Al-LI fuselage and more 3D-printing.
3. Better fuselage design with faster boarding or better medium range comfort.The A320 fuselage was a great design in the late 70’s. It takes container freight and has comfortable 18’’ seating. That said, the MC-21 shows what is possible. With only 0.8% more wetted area compared to the A320, it adds an incredible 11cm width to the cabin. This additional width does not only provide wider seats (especially welcome for medium range) but it is also incredibly flexible even allowing for a 27.6’’ aisle for fast boarding. Something which the likes of Ryanair and Asian carriers will very much appreciate.
4. Length/capacity better adjusted to market demand.The A320’s length is not that well optimized. It could use two additional rows to creep up to the 200 limit, the A321 does not reach the 250 limit either and the gap between the two is rather large. No one buys the A319 because no one needs the extra range and rather takes the lower CASM of the A320.
5. More room for high by pass ratio engines.
A new design can create room for higher bypass ratio engines. Which especially for the medium range NSA could be built in where as for A321 would require more effort.
6. More capability.
A new wing/wingbox allows for MTOW and fuel capacity that the XLR can’t match. Airbus can respond, but at significant investment.
Concluding.So now we’ve identified a few critical areas where a Boeing NSA could have an advantage over the A320. Some Airbus could match at reasonable additional investment (fuselage length, composite wing/wingbox, AL-Li, engine clearance). But regarding ultimate production efficiency, fuselage geometry Airbus won’t be able to fully answer with the A320.
Design definition.Now that we’ve identified the advantages a Boeing NSA could provide, let’s look how that would translate into the NSA’s design definition.
1. Range reset and weight reduction.
2. Common fuselage.
3 Cabin and seating width
4. NSA short range.
5. NSA medium range.
1. Range reset and weight reduction.Resetting to a lower range. For the short range version of the NSA, Boeing could start with resetting the range to stay in line with the majority of missions. Future efficiency improvements will allow it the gain range, but it’s important to limit the weight while keeping a non-foldable 36m wing. At the start Boeing won’t be able to ramp up to 50+ planes a month so this is not that important, future updates will allow it to close the gap.
2. Common fuselage.The Boeing NSA short range and medium range would use the same fuselage dimensions and production line. After ramp up giving the NSA medium range less of an economy of scale disadvantage compared to the A320 variants. As said, the MC-21 shows the way here. Providing extra space for a wider aisle (short haul boarding speed) or seat (medium range comfort) without any significant penalty in wetted area or weight. This would be perfect for the NSA short and medium range common fuselage. The fuselage would be AL-Li to keep weight as low as possible relatively to production cost and capacity.


3. Cabin and seating width:
As visible in the above image, the MC-21 is much wider (11cm) and extremely flexible within a comparable fuselage circumference (+0.8%). Carriers can choose between very fast boarding with 737 seating comfort and a 70cm aisle to very comfortable medium range seat and standard A320 width aisles and everything in between.
4. NSA short range.The NSA short range would cover three lengths with single class 28’’ pitch capacity of 170, 200 and 250 seats. We will call this the 808.
5. NSA medium range.The NSA medium range covers two lengths. It has a separate wingbox/wing and landing gear with much more in wing fuel capacity. We will call this the 818.
Boeing NSA short and medium range proposal.
The 808:The lighter of the two narrow-bodies. Range numbers suitable for the vast majority of short haul missions, but without being overly capable/heavy. Replaces the 737MAX and competes with the A220 and A320. Low cost carries will choose the config. 1 seating arrangement with above 737+ seating comfort and 70cm isle for fast boarding. Others will choose config. 2 with A320 seating width but with the flexibility of a 61cm aisle.
It has non-folding composite wing that, due to the limited MTOW, is very efficient within its 35.9m span.
The 808-2.The 808-200 would be the smallest of the family. It would compete with the A220 and to a certain degree the A320. Why would it sell when for instance a 737-7 MAX or A319 are dead in the water? Two reasons, it’s got two extra rows compared tot the A319 and more importantly, the model above is more range limited, so carriers needing the flexibility of more than 3.200Nm can’t take the model up to reduce CSAM.
The 808-3.The bread and butter model. With a 200 max capacity @28 pitch it will maximize crew potential. One on one replacement for the 737-8 but much lighter and more comfortable/flexible. A possible simple stretch to a 400 is possible over time with efficiency and MTOW improvements, subsequently dropping the 808-200 from the range.
The 808-5.Lighter competitor to the A321 with more capacity up to the 250 crew limit. Range is limited to 3.000Nm for weight reasons. Plenty for the vast majority of missions and will evolve to have more range with future improvements. Carriers who need more range can either pick the 300 or the 818 or buy an A321.
The 818:The medium range version of the common narrow-body fuselage, with a different wing/wingbox and landing gear. It has a 41m wing folding to 36m for maximum flexibility. Alternatively, it could have an even more efficient 43m wing, but that means being limited to 52m gates. Competes with the XLR and is also a replacement in the 757 and 767 market. Compared to the XLR:
- It uses lighter materials (Al-Li fuselage, composite wing)
- Has much more payload/range
- Has more capacity
- Carries all its fuel in its wing (less stress/weight in the wingbox and more cargo space),
- Has less induced drag due to the increased wingspan
- Has a much more comfortable and roomy cabin for medium haul.
The 818-5.With 5.200Nm range it will open up new single aisle markets. Most carries will probably choose config. 3 seating with a 48,4cm aisle (boarding speed is not priority in a 5.200Nm aircraft), maximizing seating comfort with on average 18.7’’ wide seat. Much more comfortable than either XLR, 757 or 767 seating. In fact, more comfortable in economy than most airplanes currently flying. All this at only 0.8% circumference penalty compared to the A321.
The 818-6.Simple stretch of the 500 with 4.500Nm range. It has the capacity and range to serve a significant part of the 767 market. Again, most will probably choose config. 3 seating for extra seating comfort, while some will choose config. 2 with still comfortable seating and at 61cm, more aisle flexibility.