Abstract: A method for forming an aircraft component includes forming an inner portion of the aircraft component. The method further includes forming an outer layer of the aircraft component using extrusion of an elastomeric material. The method further includes coupling the outer layer of the aircraft component to the inner portion of the aircraft component.

Abstract: An aircraft wing may comprise an airfoil having deicing zone, an anti-icing zone, and an ice runback control zone. An aircraft wing may comprise an electro-thermal ice protection system disposed in the aircraft wing. The electro-thermal ice protection system may be disposed along the deicing, anti-icing, and ice runback control zones of the airfoil to improve aerodynamic performance of the aircraft and reduce ice formation along the wings of the aircraft.

Abstract: A multilayer heating structure for controlling ice accumulation on a surface of an aircraft includes a carbon nano-tube (CNT) heater. The heater includes: a CNT layer; a first encapsulation layer disposed on a first side of the CNT layer formed of a first encapsulation layer thermoplastic material; and a second encapsulation layer disposed on a second side of the CNT layer formed of a second encapsulation layer thermoplastic material. The structure further includes for and aft composite structures. The first and second encapsulation layer thermoplastic materials have higher melting temperatures that one or both the fore composite structure thermoplastic material and the aft composite structure thermoplastic material.