AIP Precision Machining is proud to officially be AS9100:2016 certified as part of our dedication to quality in machining for aerospace applications. To share what that means, we’ve put together the following article to explain what AS9100D:2019 certification is and how we achieved it.

 

What is the AS9100D:2016 Standard?

 

AS9100 is a company level certification based on the ISO 9001 quality standard requirements, but with additional requirements based on the needs of the aerospace industry. These satisfy both ISO 9001 quality standards and DOD, NASA and FAA requirements.

 

This certification is based on “Quality Management Systems – Requirements for Aviation, Space and Defense Organizations,” a standard published by the Society of Automotive Engineers (SAE). A third-party certifying body issues AS9100D:2016 certification. Part of this process includes annual or regularly scheduled audits to ensure compliance with the AS9100 standard.

 

AS9100D is meant for any organization that does business in the aerospace sector, including suppliers, contractors and manufacturers, such as AIP. It’s an internationally accepted standard, though different countries use their own numbering conventions.

 

As of this blog, AS9100D:2016 is the most recent version of the AS9100, revising the previous issue, AS9100C.

 

What about this certification helps AIP Precision Machining serve the aerospace market?

 

For the past 36 years, AIP Precision Machining has been supplying mission-critical polymer and composite components to Tier 1 through 3 aerospace OEMs. The latest AS9100D certification was required as a means to help open new “doors” in this marketplace for AIP. We were already the global leader for technical know-how and capability when considering supply options for aerospace like services due to our talented and advanced team. 

 

Similar to a job application, great candidates are many times excluded from opportunities due to lacking minimum accreditations. In our journey to offer our talent and services to new US-based or globally located aerospace OEMs, AS9100 certification allows AIP to showcase our capabilities for this market.

 

“There is no doubt in my mind that AIP is and always had been overly equipped to provide mission-critical precision aerospace components,” said John MacDonald, President of AIP Precision Machining. “It is just that now we have achieved the accreditation to show those who do not know of us that we are capable.”

 

What about AIP Precision Machining allows us to achieve AS9100D:2016 certification?

 

“Anyone who tells you that it is not about the people is wrong,” said MacDonald. “Leadership provided the vision and desire to seek out AS9100D certification, but our awesome team at AIP ran the marathon and got us over the finish line. It is also our team who will maintain and continually enhance those key processes to make us better every day at serving our valued customers.”

 

Want to contact us about aerospace manufacturing?

Get in touch with us online, or see our  AD9100D:2016 certification

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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.

 

Download Our Case Study

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With over two 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 and defense 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.

 

Here are some specific examples of thermoplastic materials commonly used in the Aerospace & Defense industry.

 

ULTEM-PEI

ULTEM – PEI

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

 

 

CELAZOLE - PBI

CELAZOLE – PBI

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

 

 

RYTON – PPS

RYTON’s inherent fire retardancy, thermal stability, and corrosion resistance make it perfectly suited for aerospace applications, while its dimensional stability means even the most intricate parts can be manufactured 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.

 

 

 

DURATRON PI

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 high wear and friction resistance, VESPEL performs with excellence and longevity in severe aerospace environments. VESPEL is a trademark material of DuPont and can be provided in direct formed blanks or finished parts directly from DuPont. AIP has provided precision machined components from DuPont manufactured rod and plate stock. You can typically find VESPEL used in high temperature and high-speed bearing and wear applications, such as stator bushings.

 

 

TORLON

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. 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. PAI components fabricated from extruded shapes that require optimization of chemical resistance and/or wear performance often receive a post-curing cycle. You can find TORLON parts in structural, wear and electrical aerospace applications.

 

 

TECHTRON

TECHTRON – PPS

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

 

 

 

RADEL

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 mean it performs well even under autoclave pressure. Importantly, RADEL R5500 meets the stringent aircraft flammability requirements of 14CFR Part 25. These allow the aircraft design engineer to provide lightweight, safe and aesthetically pleasing precision components for various aircraft interior layouts. RADEL can also be polished to a mirror finish and is FDA and NSF approved for food and beverage contact.

 

 

 

KEL-F

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

PEEK can be used continuously in temperatures of 480°F (250°C) and in hot water or steam without permanent loss of 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. These aren’t the only reasons that PEEK is an increasingly popular choice for metal replacement in aerospace, however. Many manufacturers prefer PEEK for its lightweight nature, mechanical strength, creep and fatigue resistance, as well as its ease of processing. These and other exceptional physical and thermal characteristics make PEEK a versatile thermoplastic polymer for 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

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.

 

 

 

 

Explore Materials Inventory

or request a quote HERE.

 

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Aerospace Manufacturing Company

When looking to design a custom critical component for the aerospace industry, finding the right plastics manufacturer is just as important as deciding what resin works best for your project’s needs. The use of high performing plastics and thermoplastics such as ULTEM, TORLON, PEEK, and RADEL has quadrupled in aerospace design over the last 45 years thanks to their unique dynamic properties, and with them comes the need for precise machining and manufacturing.

 

Here are 5 considerations you should take into account before choosing your aerospace plastic parts manufacturing company:

 

Capabilities & Competency

 

Before hiring a plastics manufacturing company, first ensure that they have the plastic designing and production capabilities necessary to handle your aerospace project’s needs. The three main plastic production processes are 3D Printing, Injection Molding and Plastics Machining. Discovering which technology is most appropriate for your project is dependent on your project’s requirements… and the plastics manufacturer you decide on should be able to tell you the pros and cons of each technology.

 

The manufacturer you choose should also have the ability to navigate from your product’s initial vision through its production, addressing quality and customer care every step of the way. They should be able to competently handle the raw plastic materials of your choice as well, so that you receive the highest quality product in regards to cost, time, precision, efficiency, materials and more. Your project, regardless of specificity, can be machined into a highly precise and extremely resilient product.

 

Here at AIP Precision Machining, our decades of experience working with ULTEM, TORLON, PEEK, and RADEL high performing plastics ensures smooth navigation from your project’s start to finish.

 

 

Industry Standards

 

Product manufacturing companies must follow industry standards like International Organization for Standardization (ISO), Food and Drug Administration (FDA), International Traffic in Arms Regulation (ITAR) and more in order to ensure that their products hold up to specific requirements. Be wary of companies that have a default “Standard” methods—these are made-up specifications that do not follow recognized, insured specifications.

 

Take a careful look at a company’s ISO certifications. For instance, ISO 9001 is focused on meeting customer expectations, continually delivering customer satisfaction and it requires an organization to demonstrate constant improvement… If an organization doesn’t have this regulated license, you may want to ask them why.

 

Also, consider other notable ISO certifications like the AS9100 standard which is similar to the ISO 9001 standard, but with additional requirements for aerospace manufacturing that are tailored to a particular industry’s quality system expectations and regulatory requirements.

 

Here at AIP Precision Machining, not only are we registered to these standards, but we are registered to the most recent version of the ISO standards.

 

Additional Services

 

Plenty of plastic manufacturing firms offer consulting services as well as developmental processes. Going with a plastic product manufacturing company that has manufacturing conceptualization engineers can help in the long run if your project requires any design modifications. Engineering support also ensures efficiency through every step of your project’s progression.

 

Some plastics manufacturers also offer quality assurance measures. Not every company guarantees that their end products will hold up to your specifications but the firms that do will additionally offer services focused on comprehensive product design, development, patent registration guidance and prototype creation.

 

Here at AIP Precision Machining, we’re proud to offer a complete and effective quality assurance process that focuses on product quality, fast delivery, and cost-effective options.

 

Domestic vs. Overseas

 

If you decide to use an overseas factory, asking the right questions is critical to determine if they have the capabilities, credentials, and experience to become your trusted partner. It can often be difficult to find a reliable company that delivers high quality work. Some ways to find the best plastic manufacturer overseas is by asking for referrals, actually flying to their location, and asking a lot of questions and paying close attention to their responses. Many overseas factories will usually have a U.S.-based agent to represent them. If you find a company that seems like a good fit, ask to contact their domestic agent.

 

Domestic manufacturers, meanwhile, greatly reduce delivery times and shipping expenses; one who is in your same time zone allows for easy communication and improved customer services. There’s also the advantage that U.S. manufacturers have higher quality and labor standards, greater payment security, and high intellectual property right protection.

 

AIP Precision Machining is headquartered in Daytona Beach, Florida with an additional sales office in southern California. We provide an “open door” policy to our facility for potential and existing clients.

 

Experience & Expertise

 

Checking the track record of a company is important to get a clear outline of their performance, customer satisfaction, and overall product deliverability. Ask about their work history to see their range of experience and their level of expertise with aerospace projects similar to yours.

 

For instance, we at AIP Precision Machining have worked with leading aerospace and defense engineers and contractors such as Lockheed Martin, BAE Systems, and GE Aviation. With our 35+ years of polymer machining experience, we’re ready to take on the most stringent challenge to meet your needs.

 

If you’re interested in learning more about how to choose a plastic product manufacturer for your critical aerospace components, feel free to reach out to us online or call us at +1 386.274.5335 for a free consultation with one of our highly-skilled engineers.

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Earlier this month, we were pleased to attend the QAADS Symposium and present our case study, “The Right Stuff / Aircraft Galley Applications”.

 

In this partner application study, we detailed:

 

1. The appropriate steps in finding the right material for interior private jets.

2. Determining whether the said material will meet both FDA and FAR 25.853 requirements after manufacturing.

3. How unique technical capabilities can contribute to a better product without sacrificing fast delivery.

4. How AIP was able to machine a part other shops are not capable of manufacturing.

 

By providing a comprehensive understanding of what technologies are available—compared to that of the competition—we were excited to present the latest in plastic precision-machined components, illustrating with empirical data how the AIP Precision Machining team solved the aircraft’s application requirements.

 

The QAADS brings engineers in the aviation, aerospace and defense fields together with leading advanced plastics manufacturers to address concerns and challenges faced by the industry with actionable strategies.

 

Looking towards next year, we’re very excited for the 2018 QAADS meeting.

 

If you’d like to learn more about the technical and flexible manufacturing and materials solutions AIP can provide, please reach out to us at 386-274-5335 or email AIP.Sales@AIPprecision.com.

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