Common Thermoplastic Materials in Aerospace & Defense

January 27, 2020

With over three decades of experience machining precision plastic and composite parts for the Aerospace & Defense industry, AIP Precision Machining knows that weight and strength are critical for your flight-ready hardware. That’s why we’ve carefully selected, machined, and tested all our thermoplastic materials to various aerospace industry standards. Our lightweight polymers and composites have stable chemical and corrosion resistance, as well as improved strength to weight ratios when compared to exotic alloys and non-ferrous metals. AIP’s polymer and composite materials maintain their properties even at high temperatures.

Read more on thermoplastic materials commonly used in the Aerospace & Defense industry for every day to mission-critical applications.

ULTEM – PEI

ULTEM has one of the highest dielectric strengths of any thermoplastic material, meaning it works very efficiently as an electrical insulator. Being resistant to both hot water and steam, ULTEM can withstand repeated cycles in a steam autoclave and can operate in high service temperature environments (340F or 170C). ULTEM also has one of the lowest rates of thermal conductivity, allowing parts machined from ULTEM to act as thermal insulators. ULTEM is FDA and NSF approved for both food and medical contact and therefore is an excellent choice for aircraft galley equipment such as ovens, microwaves and hot or cold beverage dispensing systems. UL94 V-O flame rating with very low smoke output makes this material ideal for aircraft interior components.

CELAZOLE – PBI

CELAZOLE provides the highest mechanical properties of any thermoplastic above 400F (204C) and offers a continuous use operating temperature of 750F (399C). CELAZOLE has outstanding high-temperature mechanical properties for use in aircraft engines and other HOT section areas. This impressive lightweight material retains 100% tensile strength after being submerged in hydraulic fluid at 200°F for thirty days.

RYTON – PPS

RYTON’s inherent fire retardancy, thermal stability and corrosion resistance makes it perfectly suited for aerospace applications, while its dimensional stability means even the most intricate parts can be molded from RYTON with very tight tolerances. RYTON is typically used for injection molded parts, however, there is limited availability of extruded rod and plate for machining.

VESPEL or DURATRON – PI

Like RYTON, VESPEL is dimensionally stable and has fantastic temperature resistance. It can operate uninterrupted from cryogenic temperatures to 550°F, with intermittent to 900°F. Thanks to its resistance to high wear and friction, VESPEL performs with excellence and longevity in severe environments—like those used in aerospace applications. VESPEL is a trademarked material of DuPont and can be provided in direct formed blanks or finished parts directly from DuPont. AIP provides precision machined components from DuPont manufactured rod and plate stock. VESPEL is typically used in high temperature and high-speed bearing and wear applications such as stator bushings.

TORLON or DURATRON – PAI

DURATRON PAI’s extremely low coefficient of linear thermal expansion and high creep resistance deliver excellent dimensional stability over its entire service range. DURATRON PAI is an amorphous material with a Tg (glass transition temperature) of 537°F (280°C). DURATRON PAI stock shapes are post-cured using procedures developed jointly by BP Amoco under the TORLON trade name and Quadrant under the DURATRON trade name. A post-curing cycle is sometimes recommended for components fabricated from extruded shapes where optimization of chemical resistance and/or wear performance is required. TOLRON parts are used in structural, wear and electrical aerospace applications.

TECHTRON – PPS

TECHTRON has essentially zero moisture absorption which allows products manufactured from this material to maintain extreme dimensional and density stability. TECHTRON is highly chemical resistant allowing it to operate while submerged in harsh chemicals. It is inherently flame retardant and can be easily machined to close tolerances. It has a broader resistance to chemicals than most high-performing plastics and can work well as an alternative to PEEK at lower temperatures.

RADEL – PPSU

With high heat and high impact performance, RADEL delivers better impact resistance and chemical resistance than other sulfone based polymers, such as PSU and PEI. Its toughness and long-term hydrolytic stability means it performs well even under autoclave pressure. RADEL R5500 meets the stringent aircraft flammability requirements of 14CFR Part 25, allowing the aircraft design engineer to provide lightweight, safe and aesthetically pleasing precision components for various aircraft interior layouts. RADEL can be polished to a mirror finish and is FDA and NSF approved for food and beverage contact.

KEL – F

Kel-F is a winning combination of physical and mechanical properties, non-flammability, chemical resistance, near-zero moisture absorption and of course outstanding electrical properties. This stands out from other thermoplastic fluoropolymers, as only Kel-F has these characteristics in a useful temperature range of -400°F to +400°F. In addition, it has very low outgassing and offers extreme transmissivity for radar and microwave applications. Many aircraft and ground-based random applications use Kel-F.

PEEK

PEEK can be used continuously to 480°F (250°C) and in hot water or steam without permanent loss in physical properties. For hostile environments, PEEK is a high strength alternative to fluoropolymers. PEEK carries a V-O flammability rating and exhibits very low smoke and toxic gas emission when exposed to flame. PEEK is an increasingly popular replacement for metal in the aerospace industry due to its lightweight nature, mechanical strength, creep and fatigue resistance, as well as its ease in processing. Its exceptional physical and thermal characteristics make it a versatile thermoplastic polymer in many aerospace applications. AIP has provided flight control, fuel system, interior, engine and aerodynamic related PEEK components for various aircraft OEM and MRO providers worldwide.

KYNAR – PVDF

Another example of thermoplastic materials used in aerospace and defense is KYNAR, or PVDF. This polymer has impressive chemical resistance at ambient and elevated temperatures, as well as good thermomechanical and tensile strength. KYNAR is extremely durable due to its weather-ability and toughness even in the most severe environments. In addition to being flame-resistant, KYNAR is easy to machine, too. You can typically find KYNAR components in pipe fitting and various fuel or other fluid-related precision manifolds or connectors.

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What Can This Polymer Do? ULTEM

January 21, 2020

PART SUMMARY:

One of the high-performance thermoplastics that AIP machines is Polyetherimide (PEI), known by its tradename ULTEM. Due to its weight-saving properties, high chemical and hydrolysis resistance and tensile strength, ULTEM is popular across several industries: Automotive, aerospace and defense, electrical and electronic market, medical and life sciences and industrial applications and appliances. Read on to learn about what this incredible polymer can do!

MATERIAL PROPERTIES:

Polyetherimide (PEI) is an amorphous thermoplastic. Polyetherimide was developed to provide sufficient flexibility and good melt processability while maintaining excellent mechanical and thermal properties.

Key properties of ULTEM PEI include:

Handling at temperatures up to 340°F (171°C)
Heat Resistance
Flame Resistance
Chemical Resistance
High Rigidity
Highest Dielectric Strength
Hydrolysis Resistance
Low Thermal Conductivity

ULTEM Applications

As mentioned previously, ULTEM is a highly sought-after thermoplastic for weight-saving capabilities in aerospace components to reusable autoclave sterilizations in medical applications. However, it’s most commonly used in high voltage electrical insulation applications.

Common uses include:

Analytical Instrumentation
Dielectric Properties Required
Electrical Insulators
High Strength Situations
Reusable Medical Devices
Semiconductor Process Components
Structural Components
Underwater Connector Bodies

So, what can this polymer do? Let’s take a closer look at how ULTEM (PEI) is applied in the Aerospace & Defense, Medical & Life Sciences and Specialized Industrial markets:

WHAT CAN ULTEM DO FOR AEROSPACE & DEFENSE?

In the Aerospace & Defense Industry, ULTEM is often applied to aircraft components for weight reduction in place of metal parts. Additionally, since it has a high thermal resistance rating, polymer components have the benefit of evading radar detection in military aircraft.

AIP machines ULTEM 1000 & ULTEM 2300

ULTEM 2300 is a 30 percent glass filled version of virgin ULTEM 1000. The addition of glass increases ULTEM 1000’s dimensional stability by almost three times.

For over three decades, AIP has provided flight control, fuel system, interior, engine and aerodynamic-related ULTEM components for various aircraft OEM and MRO providers worldwide. As this industry continues to expand, evolve and innovate, the demand for high-performance materials like ULTEM contribute significantly to streamlined operations.

WHAT CAN ULTEM DO FOR MEDICAL & LIFE SCIENCES?

In the Medical Industry, biocompatibility and sterilization are paramount to medical instruments and implants. ULTEM is often a popular choice in this sector due to its resistance to chemicals and lipids. Polyetherimide also withstands dry heat sterilization at 356°F (180°C), ethylene oxide gas, gamma radiation and steam autoclave.

Some popular medical applications include disposable and re-usable medical devices and medical monitor probe housings. These could be surgical instrument handles and enclosures or non-implant prostheses. It gets extensive use in membrane applications due to its separation, permeance and biocompatible properties.

WHAT CAN ULTEM DO FOR SPECIALIZED INDUSTRIAL Sectors?

At AIP, we precision machine ULTEM for many specialized industrial applications as well: automotive, electrical and metal replacement, to name a few. Despite the diversity of these industrial applications, we have the inventory and machining capabilities to provide solutions for any project specifications.

PEI is most often used in electrical and lighting systems in the automotive market for its high heat resistance, mechanical integrity and strength. Principal automotive applications include: transmission parts, throttle bodies, ignition components, thermostat housings, bezels, reflectors, lamp sockets and electromechanical systems.

The electrical and electronic markets demand high heat resistant materials. ULTEM is an excellent choice for applications such as electrical circuit boards, switches, connectors, electronic chips and capacitors.

As discussed previously, thermoplastics like ULTEM often replace metal parts in industrial applications. For this reason, it’s often used in housewares, especially fluid handling systems. Some of these applications are: HVAC equipment, microwave cookware, steam and curling irons, dual-ovenable trays for food packaging that meets FDA food packaging requirements.

What can AIP Precision Machining do for you?

From concept to completion, our team of engineers will work with you to realize the final product. With some of the fastest lead times in the industry, our unrivaled technical experts we can tackle your polymer challenges.

What Can This Polymer Do? Supportive Information

Medical Sector Biomaterials Guide

Energy Sector Materials Guide

Aerospace Sector Materials Guide

Amorphous Materials

Aerospace Case Study: Weight-saving Polymers

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Machining Celazole PBI: A Plastics Guide

April 29, 2019

An Informational Brief on Polymer Machining

Celazole, known as Polybenzimidazole (PBI), is a synthetic fiber characterized by exceptional thermal and chemical stability. PBI is commonly used in electrical insulators and high strength situations, where it shines due to its compressive strength and insulation properties.

Our latest machining guide discusses what goes into machining Celazole and how its considerations differ from other manufacturing options such as metal machining, injection molding, and 3D printing.

How does AIP approach Celazole and its machining process? To start, we’ll explain the difference between machining PBI, a thermoplastic, and machining thermosets.

Machining Thermoplastics vs Thermosets

We’ve already said that Celazole is a thermoplastic, but what does that mean exactly?

All polymers can more or less be divided into two categories: thermoplastics and thermosets. The main difference between them is how they react to heat. Thermoplastics like Celazole, for example, melt in the heat, while thermosets remain “set” once they’re formed. Understanding the technical distinction between these types of materials is essential to CNC machining them properly.

What type of thermoplastic is Celazole in particular? PBI is an amorphous engineering thermoplastic.

PBI is characterized by high strength; it exhibits excellent thermal stability, is hydrolytically stable after exposure to high-pressure steam or water, is broadly resistant to hydrocarbons, alcohols, weak acids, weak bases, hydrogen sulfide, chlorinated solvents, oils, heat transfer fluids and many other organic chemicals.

Properties & Grades of Machined Celazole

Celazole PBI is one of the highest performing thermoplastics on the market today; it has the lowest coefficient of thermal expansion of all unfilled plastics. At above 400°F (204°C), Celazole possesses the highest mechanical properties of any thermoplastic. By itself, PBI offers a continuous use operating temperature of 1,004°F (540°C). Even after being submerged in hydraulic fluid at 200°F (93°C) for thirty days, Celazole retains 100% tensile strength.

When you combine those exceptional qualities with excellent wear and frictional properties, as well as extreme resistance to chemicals and hydrolysis, it’s no wonder that Celazole excels in industries that require high-performance in hostile environments. For example, semiconductor parts made with Celazole can last twice as long as those made with polyimides.

Other applications that Celazole is commonly machined for include gas plasma equipment, aircraft engine components and other applications for “hot” section areas or environments with harsh chemicals. Whenever dielectric properties are required or high-strength situations arise, Celazole PBI is an ideal material for your application.

We regularly machine various grades of Celazole at AIP Precision Machining, including Celazol U-60 and Duratron PBI.

Machining Celazole PBI

Annealing Celazole

The process of annealing and stress-relieving Celazole reduces the likelihood of surface cracks and internal stresses occurring in the material. Post-machining annealing also helps to reduce stresses that could potentially contribute to premature failure.

Machining Celazole

Celazole is known for its extreme hardness, which poses a challenge to HSS machining. Instead, carbide and polycrystalline diamond tools are recommended for machining Celazole PBI.

Keep in mind that Celazole PBI is notch sensitive as well and that high tolerance components machined from this thermoplastic should be stored and sealed to prevent any dimensional changes from moisture absorption.

We also suggest non-aromatic, air-based coolants to achieve optimum surface finishes and close tolerances. Coolants have the additional benefit of extending tool life as well.

Preventing Contamination

Contamination is a serious concern when machining polymer components for technically demanding industries such as medical and life sciences. To ensure the highest level of sanitation down to the sub-molecular level, AIP Precision Machining designs, heat-treats and machines only plastics, with any sub-manufactured metalwork processed outside our facility.

Celazole PBI Machining Guide: Supportive Information

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Machining Teflon: A Plastics Guide

March 27, 2019

An Informational Brief on Polymer Machining

Polytetrafluoroethylene (PTFE) is a fluorocarbon-based polymer, known more commonly as Dupont’s brand name Teflon®. The enhanced electrical properties, high-temperature capabilities and chemical resistances of this thermoplastic make it a favorite for backup rings, coatings, distribution valves, electrical insulation applications and more.

Our latest machining guide discusses what goes into machining Teflon and how its considerations differ from other manufacturing options such as metal machining, injection molding, and 3D printing.

Read on to learn more about Teflon’s machining, applications and properties in AIP’s informational polymer brief below, starting with the difference between working with a thermoset and a thermoplastic.

Machining Thermoplastics vs Thermosets

We’ve already said that Teflon is a thermoplastic, but what does that mean exactly?

All polymers can more or less be divided into two categories: thermoplastics and thermosets. The main difference between them is how they react to heat. Thermoplastics like Teflon, for example, melt in heat, while thermosets remain “set” once they’re formed. Understanding the technical distinction between these types of materials is essential to CNC machining them properly.

What type of thermoplastic is Teflon in particular? PTFE is a fluoropolymer, making it a semi-crystalline thermoplastic. As a fluoropolymer, PTFE possesses an inherent high resistance to solvents, acids and bases.

Properties & Grades of Machined Teflon

Teflon has excellent electric stability in a wide range of conditions and environments, and its coatings are popular in the aerospace sector. Offering excellent chemical resistance and sliding properties, PTFE finds many applications in seals, housings, linings and bearings. Teflon also maintains very good UV resistance, hot water resistance and electrical insulation at higher temperatures.

Unfilled PTFE is chemically inert and has the highest physical and electrical insulation properties of any Teflon grade. Mechanical grade PTFE is often made up of reground PTFE and exists as a cost-effective alternative for industries that don’t require high purity materials while providing superior compressive strength and wear resistance to virgin Teflon.

There are several different modified PTFE materials available with unique properties. Many of these modified grades offer greatly reduced deformation percentages under load, as well as a lower coefficient of friction. These include glass-filled, nanotube, synthetic mica and carbon-filled grades. Teflon (PTFE) is more commonly used as an additive to numerous other base polymers in order to provide reduced friction and wear properties.

Some of the PTFE grades we regularly machine at AIP include FLUOROSINT 207, FLUOROSINT 500, DYNEON, SEMITRON, ESD 500 HR, and SEMITRON PTFE.

Machining Teflon

Annealing & Stress Relieving Teflon

The process of annealing and stress-relieving PTFE reduces the likelihood of surface cracks and internal stresses occurring in the material. Post-machining annealing also helps to reduce stresses that could potentially contribute to premature failure. AIP’s special annealing process for Teflon is designed to take the specific properties of PTFE into account, and we advise anyone working with PTFE to hire a manufacturer that understands its unique demands.

Machining Teflon

PTFE’s density and softness make it deceptively easy to machine, and in virgin grade, has a temperature range from -450°F to +500°F (-267.7°C to +260°C). Teflon has low strength when compared to materials like Nylon, which has almost two to three times the tensile strength of Teflon. You’ll want to use extremely sharp and narrow tools to work with this material.

Teflon’s high coefficient of expansion and stress creep properties can make it difficult to achieve tight machining tolerances. It’s essential to design your application with PTFE’s inherent properties in mind, instead of trying to force the polymer to act against its nature.

We also suggest non-aromatic, water-soluble coolants, such as pressurized air and spray mists, to achieve optimum surface finishes and close tolerances. Coolants have the additional benefit of extending tool life as well.

Preventing Contamination

Teflon Machining Guide: Supportive Information

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Machining Delrin: A Plastics Guide

March 1, 2019

An Informational Brief on Polymer Machining

Delrin®, also commonly known as an acetal (polyoxymethylene) homopolymer, is an impact and wear resistant semi-crystalline thermoplastic popular for a broad range of machining applications. To list just a few of its impressive qualities, Delrin offers great stiffness, flexural modulus, and high tensile and impact strength.

Our latest machining guide discusses what goes into machining Delrin and how its considerations differ from other manufacturing options such as metal machining, injection molding, and 3D printing.

How does AIP approach Delrin and its machining process? To start, we’ll explain the difference between machining Delrin, a thermoplastic, and machining thermosets.

Machining Thermoplastics vs Thermosets

We’ve already said that Delrin is a thermoplastic, but what does that mean exactly?

All polymers can more or less be divided into two categories: thermoplastics and thermosets. The main difference between them is how they react to heat. Thermoplastics like Delrin, for example, melt in the heat, while thermosets remain “set” once they’re formed. Understanding the technical distinction between these types of materials is essential to CNC machining them properly.

What type of thermoplastic is Delrin in particular? Acetal homopolymer is a semi–crystalline, engineering thermoplastic.

Properties & Grades of Machined Delrin

This strong, stiff and hard acetal homopolymer is easy to machine and exhibits dimensional stability and good creep resistance, among several other desirable qualities. Delrin is also known for its superior friction resistance, high tensile strength, and its fatigue, abrasion, solvent and moisture resistance.

The latter quality allows Delrin to significantly outperform other thermoplastics like Nylon in high moisture or submerged environments without losing high-performance in the process. In other words, Delrin can retain its low coefficient of friction and good wear properties in wet environments.

One of the main reasons for Delrin’s popularity is its sheer versatility. The above blend of unique qualities makes Delrin broadly applicable to various industries in the medical, aerospace and energy sectors. For example, you can machine Delrin for medical implants and instruments, or for industrial bearings, rollers, gears, and scraper blades. It is ideal for smaller applications at temperatures below 250 °F (121°C) and can have centerline porosity.

Some of the Delrin grades we regularly machine at AIP include:

PTFE-Filled Acetals

PTFE (polytetrafluoroethylene) filled grades of Delrin is ideal where impact strength and wear capability are of the highest importance.

Glass-Reinforced Acetals

Acetals that are reinforced with glass have a much higher strength and greater heat resistance than other grades of Delrin.

FDA-Compliant Acetals

There are FDA-compliant grades of Delrin available for use in medical and food-related applications.

Machining Delrin

It’s true that Delrin is an easy material to work with in terms of machining. It is a very stable material, which makes precise, tight tolerances easier to achieve for this thermoplastic.

While machining, keep in mind that Delrin is sensitive to heat at or above 250 °F (121°C).

Balance the material removal as best as you can to keep your dimensions stable.

We also suggest non-aromatic, air-based coolants to achieve optimum surface finishes and close tolerances. Coolants have the additional benefit of extending tool life as well.

Preventing Contamination

Contamination is a serious concern when machining polymer components for technically demanding industries such as medical and life sciences. To ensure the highest level of sanitation down to the sub-molecular level, AIP Precision Machining designs, heat-treats, and machines only plastics, with any sub-manufactured metalwork processed outside our facility.

Delrin Machining Guide: Supportive Information

General Engineering Materials

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Machining Nylatron: A Plastics Guide

November 5, 2018

An Informational Brief on Polymer Machining

Nylatron® is Quadrant’s trademark name for a whole family of wear resistant and low friction Nylon polymers, most of which are filled with molybdenum disulphide (MoS2) powder. What makes this material popular for industrial and bearing applications is its mechanical properties and impressive wear-resistance.

In our latest machining guide, we discuss what goes into machining Nylatron, and how its considerations differ from other manufacturing options such as metal machining, injection molding, and 3D printing.

Machining Nylatron: A Plastics Guide shows you how AIP Precision Machining approaches this material and its machining process. To start, we’ll explain the difference between machining Nylatron, a thermoplastic, and machining thermosets.

Machining Thermoplastics vs Thermosets

We’ve already said that Nylatron is a thermoplastic, but what does that mean exactly?

All polymers can more or less be divided into two categories: thermoplastics and thermosets. The main difference between them is how they react to heat. Thermoplastics like Nylatron, for example, melt as heat is increased to the material’s melt point, while thermosets remain “set” once they’re formed regardless of heat; rather, they simply char or burn. Understanding the technical distinction between these types of materials is essential to CNC machining them properly.

What type of thermoplastic is Nylatron in particular? As part of the Nylon family, it is a semi-crystalline, engineering thermoplastic polyamide.

Properties & Grades of Machined Nylatron

Nylatron’s main characteristics include a high mechanical strength, stiffness, hardness and toughness. As a semi-crystalline thermoplastic, Nylatron has good fatigue resistance as well. With excellent wear resistance and good electrical insulating properties, it’s not surprising that this material is often used for specialized industrial applications. One feature that’s of special interest to us at AIP is Nylatron’s ease of machinability with high precision. However, it’s also easy to extrude and fabricate.

Like Nylon, Nylatron is resistant to chemicals and hydrocarbons; the latter characteristic is especially useful in the oil and gas sector. Add in abrasion resistance, low coefficient of friction and outstanding corrosion resistance and you have a long-wearing material that can serve as a cost-effective replacement for metals and rubber.

Some of the Nylatron grades we regularly machine at AIP include:

Nylatron GSM PA6

Also known as MoS2-Filled Type 6 Nylon, this filled Nylatron grade has improved strength and rigidity over other Nylon variants, including a lower coefficient of linear thermal expansion. This is because the MoS2 (molybdenum disulphide) enhances the bearing and wear of the material without compromising its impact and fatigue resistance. This grade is often used to replace cast iron industrial applications, as lightweight Nylatron can both reduce weight and eliminate corrosion. As a result, it’s commonly used for gears, bearings, sprockets and sheaves.

Nylatron GF30 PA66

This extruded grade of Nylon 6/6 is 30% glass fiber reinforced and heat stabilized to provide improved creep resistance and dimensional stability as well as enhanced strength, stiffness and abrasion resistance. It has almost double the tensile strength of unmodified Nylon 6/6, with an elongation rate of about 1/6^th that of unmodified Nylon 6/6. It has good resistance to high energy radiation (such as X-rays or gamma- rays) and allows for higher maximum service temperatures when compared to other grades.

Nylatron LIG PA6

Nylatron LIG PA6 is an internally lubricated Nylon grade that can perform up to ten times longer than its unmodified counterpart thanks to its lubricated additives. It strikes an optimal balance of strength and toughness. This makes it work well for industrial and consumable applications including gears, industrial bearings and wear pads.

Nylatron NSM

Nylatron NSM is the highest wear resistant thermoplastic available. As a self-lubricating grade of Nylon 6, it’s designed to outperform other wear grade materials and give long-lasting part life for applications that otherwise experience continuous wear and damage, such as bearings and wear pads. Other benefits of Nylatron NSM are its ease of machining, corrosion-resistance and noise reduction.

Nylatron GSM Blue PA6

Named for its dark blue color, Nylatron GSM Blue PA6 is the first cast Nylon to combine MoS and oil for the load capacity of Nylatron GSM PA6. This material performs exceptionally in higher pressures and at low speeds of up to 40 fpm. It’s preferred over Nylatron GSM PA6 for slide pads, thrust washers and trunnion bearings due to its 20% lower coefficient of friction, 50% greater limiting PV and its lower “k” factor.

Nylatron 703XL

High precision applications machined from Nylatron 703XL benefit from its near-zero level of “stick-slip,” which eliminates chatter to allow for an incredible level of control. Nylatron 703XL possesses a good balance of strength and toughness, as well as good mechanical and electrical properties. This grade works well in critical bearing applications for construction and production equipment industries.

Nylatron MC901

Nylatron MC901 is a heat-stabilized Nylon 6 grade that offers long-term thermal stability to 260 °F. This material has high toughness, flexibility and fatigue resistance. It is used in many bearing and structural applications, its most popular being gear wheels, racks and pinions.

Machining Nylatron

Annealing Nylatron
The process of annealing and stress-relieving Nylatron reduces the likelihood of surface cracks and internal stresses occurring in the material. Post-machining annealing also helps to reduce stresses that could potentially contribute to premature failure. We recommend stress relieving Nylons in a nitrogen environment.

Machining Nylatron

As stated earlier, Nylatron precision machines easily. This makes it a popular choice for machined industrial components that require precise, tight tolerances. We advise using HSS cutters instead of carbide on Nylatron for its surface finish. Stringer or chip removal during machining of Nyaltron is critical in order to maintain tolerances and surface finish.

When under high humidity, or while submerged in water, Nylons can absorb up to 7% by weight of water. This is important to keep in mind for machining Nylatron and designing applications of the material, as this effect can result in dimensional changes and a reduction of physical properties. There are proper design techniques that can compensate for this, so be sure you’re working with a Nylatron expert.

We also suggest non-aromatic, air-based coolants to achieve optimum surface finishes and close tolerances. Coolants have the additional benefit of extending tool life as well.

Preventing Contamination

Contamination is a serious concern when machining polymer components for technically demanding industries such as aerospace. To ensure the highest level of sanitation down to the sub-molecular level, AIP Precision Machining designs, heat-treats and machines only plastics, with any sub-manufactured metalwork processed outside our facility.

Nylatron Machining Guide: Supportive Information

Nylon Variants Guide

Chemical Resistant Materials Guide

Energy Sector Materials Guide

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Where Does This Part Go?

September 26, 2018

PPS Wheel Bushing | AIP Precision Machining

If you’ve been to a popular Florida amusement park, then it’s possible you’ve encountered the latest part starring in our “Where Does This Part Go?” series.

Find out why this part really makes a “splash” in the section below…

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Machining PPS: A Plastics Guide

August 30, 2018

An Informational Brief on Polymer Machining

Did you know that PPS (or Polyphenylene sulfide) products offer the broadest resistance to chemicals of any high-performance thermoplastic? It’s no surprise that this makes them a popular choice for industrial applications such as wheel bushings, chemical pumps, and compound clamp rings for semiconductor wafers.

What goes into machining this thermoplastic, however, and how does it differ from metal machining, injection molding, or 3D printing?

With Machining PPS: A Plastics Guides, AIP provides you with a guide to this material and its machining process. First, let’s start with the basics: thermoplastics vs thermosets.

Machining Thermoplastics vs Thermosets

We’ve already said that PPS is a thermoplastic, but what does that mean exactly?

All polymers can more or less be divided into two categories: thermoplastics and thermosets. The main difference between them is how they react to heat. Thermoplastics like PPS, for example, melt in heat, while thermosets remain “set” once they’re formed. Understanding the technical distinction between these types of materials is essential to CNC machining them properly.

What type of thermoplastic is PPS in particular? It’s a semi-crystalline, high-performance thermoplastic that has an extremely stable molecular structure. The chemical resistance of PPS is often compared to PEEK and fluoropolymers.

Properties & Grades of Machined PPS

There’s a lot to like about PPS’s material properties. As we mentioned before, PPS has exceptional chemical resistance that makes its bearing grades especially favorable for the chemical industry or caustic environments. In particular, its resistance to acids, alkalis, ketones, and hydrocarbons lend PPS stellar structural performance in harsh chemicals.

Additionally, PPS materials are inert to steam as well as strong bases, fuels and acids. Combine that with a low coefficient of thermal expansion and zero moisture absorption, and you get a material that is ideal for continuous use in corrosive or hostile environments. PPS has replaced stainless steel for a lot of industrial applications for this reason.

Most impressively, PPS will not dissolve at temperatures below approximately 200 °C, no matter what solvent is used. In fact, all grades of PPS share UL94 V-0 flammability ratings, without requiring flame retardant additives, resulting in an excellent material for aircraft where flame resistance is paramount.

Some grades of PPS that we regularly machine at AIP Precision Machining include Ryton®, Fortron®, TECHTRON®, TECTRON® HPV, TECATRON PVX and TECATRON CMP.

Machining PPS

Annealing PPS

The process of annealing and stress-relieving PPS reduces the likelihood of surface cracks and internal stresses occurring in the material. Post-machining annealing also helps to reduce stresses that could potentially contribute to premature failure. AIP’s special annealing process for PPS is designed to take the specific properties of PPS into account, and we advise anyone working with PPS to hire a manufacturer that understands its unique demands.

Machining PPS

PPS is a fantastic material for machining. Its low shrinkage and stable dimensional properties make it easy to machine to incredibly tight, precise tolerances. A unique characteristic of PPS is that when dropped, it sounds just like a piece of metal hitting the floor.

PPS, like many other thermoplastics, is notch sensitive, so take care to avoid sharp corners in design. We recommend carbide tipped cutting tools for working with PPS as they provide an ideal speed and surface finish.

Preventing Contamination

Contamination is a serious concern when machining polymer components for technically demanding industries such as aerospace. To ensure the highest level of sanitation down to the sub-molecular level, AIP Precision Machining designs, heat-treats, and machines only plastics, with any sub-manufactured metalwork processed outside our facility.

To learn more, read our article “Three Ways to Ensure Sterilization in Your Plastic Machined Medical Applications.”

PPS Machining Guide: Supportive Information

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Plastics in Aerospace: The Secret to Fuel-Efficient Aircraft

July 19, 2018

How Aluminum Got Dethroned by Thermoplastics in Aerospace

Cup holders. Magazines. Suit cases. Aircraft engines. Here’s a riddle, what do these items all have in common? If you’re an aircraft operator, the answer is obvious: they all add weight, making them a drain on your fuel costs.

If weight is one of the main operating costs of an aircraft, then it’s no surprise that airlines want to lose a few pounds. Over the last 35 years, AIP has witnessed firsthand the incredible weight savings that can be gained from using lightweight polymers and composites for aerospace applications.

How Airlines “Slim Down” Operating Costs

How much can an ounce cost you? Plenty. In the case of United Airlines, removing a single ounce from its in-flight magazine has translated to saving $290,000 a year. Yes, a single ounce can hit an airline with up to six digits in costs.

If thinner paper can have such an impact on your bottom line, then you can imagine the significant cost savings that can come from manufacturing lighter aerospace components. What’s the most lightweight solution for aircraft operators today? We have one word for you: plastics.

What Makes Plastics the Secret to Aircraft Fuel-Efficiency

Aluminum was popular during the “Golden Age of Aviation” because of its strength and durability as well as its lightness when compared to other metals like steel. As a result, many aircraft components have traditionally been metal, from aircraft interiors, to landing gear, aircraft engines and structural components.

Now consider the fact that polymer and composite materials can be up to ten times lighter than metal. It’s no wonder that as more thermoplastic materials come on the market and new manufacturing opportunities arise, metal replacement has been seen as one of the best opportunities to reduce airline weight.

How big is the impact of switching from aluminum to plastic parts like PEEK and ULTEM in aerospace applications? Operators can earn weight savings of up to 60%. This translates to lower lifetime fuel costs, reduced emissions and extended flight range for operators.

“Weighing” the Option of Plastics in Aerospace

Weight alone is a massive reason to consider thermoplastics for aerospace, but weight isn’t the only factor at play in material selection.

After all, wood is lighter than metal, but there’s a reason we don’t build spruce airframes like the first plane from the Wright brothers: it wouldn’t be safe today to fly a wooden plane! Aerospace components need to be able to survive in corrosive, harsh environments as well as provide resistance to high temperatures.

In other words, it’s crucial that your mission-critical components aren’t just lightweight, but also high-performing.

At AIP, we carefully apply our decades of material expertise to select the right material for your application’s needs. Remember that your aerospace plastics manufacturer should understand the unique demands of your industry and your application, and have experience machining the material you require.

Want to learn more about how AIP reduces costs for aircraft operators?

Read how machined polymer components can take a load off aircraft interiors in our aerospace case study.

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Machining RADEL: A Plastics Guide

June 25, 2018

An Informational Brief on Polymer Machining

RADEL is a PPSU (or Polyphenylsulfone) widely considered to be the highest-performing of Solvay’s sulfone polymers. It’s no surprise then that we’ve regularly machined RADEL at AIP Precision Machining over the past three decades.

With superior impact strength and outstanding resistance to stress cracking, RADEL offers exceptional hydrolytic stability and toughness across a wide temperature range, making it a favorite of the medical, electronics manufacturing, and aerospace industries.

AIP has over 35 years of experience machining complex components from RADEL and various other thermoplastic materials. We are providing this Machining RADEL as yet another insightful technical brief about our polymer component manufacturing process, and how it differs from that of metal machining, injection molding, or 3D printing.

Machining Thermoplastics vs Thermosets

Plastic CNC machining is affected by what type of material you’re machining. Technical expertise is key to polymer machining, which is why you have to know the polymer structure and properties of RADEL before machining it.

There are two basic types of polymers: thermoplastics and thermosets. Thermoplastics soften in heat and become more fluid, while thermosets cross-link during curing, which eliminates the risk of a product re-melting in heat. Since these categories react differently to chemicals and temperature, it’s important to know that RADEL is a thermoplastic.

To be specific, RADEL PPSU is an amorphous, high-performance thermoplastic that is lightweight, available in bone-white or black colors, and can be either transparent or opaque. Like other amorphous thermoplastics, such as ULTEM, RADEL is thermoform capable, translucent and easily bonded with adhesives or solvents.

Properties & Grades of Machined RADEL

RADEL’s reputation as a high-performance thermoplastic is well deserved. RADEL PPSU has an impressive heat deflection temperature of 405°F (207°C) and is inherently flame retardant with low NBS smoke evolution, making it an ideal material choice for aircraft interiors. In addition, its retention of mechanical properties is superior to all other amorphous transparent polymers.

With improved impact and chemical resistance over PSU and PEI, RADEL PPSU has been tested for notched izod impact resistance as high as 13 ft.-lbs/in. It can endure over 100 joules of force without shattering, even with repeated exposure to moisture and extreme temperatures.

These inherent qualities allow RADEL PPSU to withstand unlimited steam autoclaving and provide RADEL with excellent resistance to EtO, gamma, plasma and chemical sterilizations as well. Unsurprisingly, its extreme thermal properties make RADEL ideal for reusable medical instruments and other applications where sterilization is key.

Not all grades of RADEL PPSU share the same exact properties, of course. Choosing the grade of your material that best meets your needs is an important part of AIP Precision Machining’s expert material knowledge.

One grade of RADEL PPSU we machine regularly at AIP Precision Machining is RADEL R5500.

RADEL R5500

RADEL R5500 is a unique polymer grade that meets the stringent aircraft flammability requirements of 14CFR Part 25, while also being a biocompatible, medical-grade resin that is FDA and NSF approved for food and beverage contact. From that, it’s clear that RADEL R5500 can be used for a wide range of applications, whether it’s for aircraft interiors, electronic burn-in sockets or surgical instruments. RADEL R5500 can be polished to a mirror finish and is available in both opaque and transparent colors.

Machining RADEL PPSU

Annealing RADEL PPSU
RADEL PPSU, like many polymers, can be received in the form of rods, sheets, tube or film. As we mentioned before, amorphous thermoplastics like RADEL are especially sensitive to stress-cracking, so stress-relieving through an annealing process is highly recommended before machining.

Annealing RADEL greatly reduces the likelihood that surface cracks and internal stresses will occur from the heat generated. Post-machining annealing also helps to reduce stresses that could potentially contribute to premature failure.

If the machine shop you are working with does not have a computer controlled annealing oven for plastics, then “head for dee hills” as they are obviously not RADEL machining experts.

Machining RADEL PPSU

Non-aromatic, water-soluble coolants are most suitable for ideal surface finishes and close tolerances. These include pressurized air and spray mists. Coolants have the additional benefit of extending tool life as well.

Many metal shops use petroleum-based coolants, but these types of fluids attack amorphous thermoplastics like RADEL PPSU. Many past experiences have shown parts going to customer without cracks, only to develop cracks over time due to exposure to metal machine shop fluids. Be sure to use a facility like AIP who machines polymers and only polymers.

Preventing Contamination

Contamination is a serious concern when machining polymer components for technically demanding industries such as aerospace and medical. To ensure the highest level of sanitation down to the sub-molecular level, AIP Precision Machining designs, heat-treats, and machines only plastics, with any sub-manufactured metalwork processed outside our facility. This minimizes the potential for metallic cross-contamination.

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