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New Hybrid Moulding Process and Material Innovations from Victrex

14 October 2014

New Hybrid Moulding Process and Material Innovations from Victrex

Victrex has collaborated with Tri-Mack Plastics to deliver unique structural aircraft solutions.

Victrex has developed a new PAEK-based polymer and an innovative hybrid moulding technology, which it claims this allows engineers to over-mould a PAEK-based composite with fibre-reinforced Victrex PEEK injection moulding materials.

According to the company, the polymeric advancement allows engineers to design stronger, lower cost components that are up to 60% lighter than typical metal and thermoset systems. By working together, Victrex and Tri-Mack Plastics Manufacturing have engineered an aerospace bracket using this new polymer and technique with the demanding performance requirements of loaded applications in mind.

Victrex explains commercial aircraft use thousands of brackets from the cockpit to the tail of the plane. The total amount of brackets on an aircraft can add a significant amount of weight especially if they are made from metal. It claims the hybrid-moulded Victrex PAEK-based composite bracket is able to deliver up to 60% weight savings compared to stainless steel and titanium while offering equivalent or better mechanical properties such as strength, stiffness, and fatigue.

“These technologies are enabling engineers to design lighter, stronger and more cost-effective solutions like the new bracket,” stated Tim Herr, Aerospace Strategic Business Unit Director for Victrex. Herr says, “This game-changing advantage over metals and thermoset composites is a result of our dedication to the future of flight.”

Victrex states Tri-Mack has a long-standing relationship with Victrex in the development of high-performance aerospace components using PAEK polymers.

“Given our expertise in the industry, we were excited to use a new polymer and process to develop an innovative product,” said Tom Kneath, Director of Sales and Marketing for Tri-Mack. Kneath added, “The design flexibility of the materials, along with the technical support from Victrex, enabled us to engineer and manufacture a PAEK bracket that can be produced in minutes compared to the hours it would take for a metal or thermoset equivalent.”

Photo provided by Victrex





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