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The surprising reason you'll never see a square plane window.

The humble aeroplane window - a small portal that passengers fight over during boarding - has a fascinating and crucial reason behind its distinctive round shape. 

While most of us are preoccupied with securing a window seat for the best views or a comfortable spot to rest our heads, the circular design of these windows represents one of aviation's most important safety developments, born from tragic lessons of the past.

In the early days of commercial aviation, planes featured square windows, which seemed like a logical choice for aircraft manufacturers. 

However, this design choice proved to be catastrophically flawed. 

In the 1950s, two devastating accidents involving the de Havilland Comet, the world's first commercial jetliner, led to a new understanding of aircraft structural engineering and forever changed plane windows.

Why don't planes have square windows?

The main problem with square windows lies in their corners. These sharp angles create weak points in the aircraft's structure where stress concentrates during flight. 

At high altitudes, where the pressure difference between the inside and outside of the plane is significant, these stress points become particularly dangerous.

The tragic crashes of the de Havilland Comets occurred due to metal fatigue. The repeated cycle of pressurization and depressurization during flights caused microscopic cracks to form at stress points, including the corners of the square windows, eventually leading to catastrophic failures.

TikTok famous pilot, Captain Steve, took to his social media to share more. 

"They lost a few aeroplanes in mid air, the planes literally came apart, because the square windows created a hairline crack in the edge," he said. "The airframes actually came apart."

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"In the analysis they said, 'We're going to engineer these things different. Make them round, they're stronger, they won't crack.' Never had a problem since."

Why are round plane windows better?

Round windows eliminate these stress points entirely. The curved shape allows the pressure to be distributed evenly around the window's edge, preventing the concentration of stress that occurs in corners. This simple yet ingenious design change has become a standard safety feature in modern aviation.

Today's aircraft windows are actually made up of multiple layers of acrylic and glass, each serving a specific safety purpose. The outer pane handles the pressure differential, the middle pane acts as a fail-safe, and the inner pane protects the other layers from passenger interference and prevents scratches.

What is the small hole in the plane window for?

Modern aeroplane windows include a small hole at the bottom, known as the "bleed hole." This tiny feature serves an important purpose: it equalises the pressure between the window panes and prevents the windows from fogging up during flight.

Why we love round plane windows.

While the round window design was first implemented for safety reasons, it has also enhanced the flying experience for passengers. The curved shape actually provides better visibility than square windows would, allowing travellers to enjoy clearer views of the world outside.

So, the next time you're gazing out of an aeroplane window at 35,000 feet, take a moment to appreciate its round shape. 

Feature image: TikTok/Getty.

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