New hybrid moulding process

Paul Boughton

Victrex has developed a new PAEK-based polymer and a hybrid moulding technology. This allows engineers to overmould a PAEK-based composite with fibre-reinforced VICTREX PEEK injection moulding materials.

The polymeric advancement allows engineers to design stronger, lower cost components that are up to 60% lighter than typical metal and thermoset systems.

Victrex and Tri-Mack Plastics Manufacturing Corporation have engineered an aerospace bracket using this new polymer and technique with the demanding performance requirements of loaded applications in mind.

The development of technologies for the aerospace industry is making significant progress not only from a material perspective, but from a processing standpoint as well. Engineers are requiring lightweight, complex parts at lower costs, higher processing efficiencies, and improved mechanical properties. This can be delivered by using the hybrid moulding process.

Victrex has collaborated with Tri-Mack Plastics Manufacturing Corp, moulder of high temperature thermoplastic resins and composites for the aerospace sector, to deliver structural aircraft solutions

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. 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. 

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