Plastics - AIP Precision Machining

Common Thermoplastic Materials in Aerospace & Defense

December 20, 2017

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 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 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.

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 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 – 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 – 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 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 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

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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Top 5 Things to Look for When Choosing an Aerospace Plastics Manufacturer

December 18, 2017

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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QAADS Symposium: Where Aviation Meets Innovation

November 21, 2017

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:

The appropriate steps in finding the right material for interior private jets.
Determining whether the said material will meet both FDA and FAR 25.853 requirements after manufacturing.
How unique technical capabilities can contribute to a better product without sacrificing fast delivery.
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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Settling the Debate: 3D Printing, Injection Molding or Plastic Machining

July 27, 2017

To a certain degree, 3D printing, injection molding, and plastic machining technology overlap in their capabilities and offerings. But which fabrication process is most appropriate for your project? What are their key differentiators? The following article assesses the utility of each technology with regard to precision, efficiency, materials and more.

Capabilities

3D printing is an additive manufacturing process that prints layers of plastic substance in three dimensions onto a single point. The popularity of 3D has grown significantly over the past few years, and it can easily be used for rapid prototyping, DIY production and manufacturing by small-scale engineers or designers. Many of the advances in 3D printing have been focused on bringing down prices, rather than technological advancement so that it can be more accessible to “mom-and-pop” users who are otherwise not eligible for the more expensive and advanced manufacturing processes.

Another additive technology, injection molding is a manufacturing process in which parts are produced by injecting materials in liquid form into a mold. Commonly performed with thermoplastic polymers, it can be used with a variety of other metal and glass materials. Small pellets of material are heated into a molten liquid which is then injected into a mold at high pressures and rapidly cooled—causing it to harden—and then ejected from the mold, exposing the part to air. Two of its key benefits include a fully automated process—permitting very high rates of production—and also that its molds allow for highly detailed and intricate parts.

Finally, plastic machining, or CNC (Computer Numerical Control) plastic machining or CNC milling, involves the precise removal of layers from a material. Typically beginning with a block of the desired plastic material, plastic machining involves removing material layers at a time and allows for many different materials to be used. Introduced by MIT during the 1950s, this technique utilizing drilling tools to carve plastics—and because it’s computer-controlled, extremely precise and tolerant products are achieved.

Comparing the Options

	3D Printing	Injection Molding	Plastic Machining
Cost	Very low cost when you need 1-10 rapid design iterations on a prototype part.	Because creating (or updating) a mold can end up being much more expensive than the actual order itself, this is only cost-effective with very large-scale projects.	Significantly cost-effective when you need a few parts up to a few thousand.
Design	Designs can be highly personalized and unique—this technology is often used by artists and creative professionals.	Allows for deep features, square holes and living hinges to be produced easily.	High design flexibility at lower costs are allowed.
Material	Very limited in comparison to other plastic fabrication and unable to achieve the same smooth surfaces as the other technologies.	Injection molding has a much wider range of materials available for use compared to 3D printing but is more limited than CNC machining.	Broadest range of materials are allowed—CNC plastic machining also achieves the smoothest finish with the fewest imperfections.
Production	Fast and extremely convenient—small products can be machined in seconds.	Requires time to make the mold but once the mold is finalized, production moves quickly.	One of the fastest forms of fabrication and can easily scale between small and large outputs.
Tolerance	3D printed prototypes are not typically finished parts and are much more likely to delaminate. Best for home and personal consumer-grade products.	Parts are molded at tighter tolerances than 3D printed parts but are not as tolerant as plastic machined parts.	Highest tolerances available—parts are able to reach +/- 0.002 mm and are best for demanding industries like aerospace and defense, medical and life sciences and power generation.

Why Plastics Machining Ranks Best

From the above chart, you can see the differentiators of each fabrication process. However, we’ve found that CNC plastic machining is by far the most precise and beneficial process for custom applications.

Cost-wise, plastics machining is the most effective for any project that requires unique, strong designs. 3D printing is the cheapest form of fabrication but you get what you pay for with that medium… and the quality typically just isn’t there. Injection molding, meanwhile, offers much stronger products than those that are 3D printed, but modifications to a mold are extremely expensive and injection molded products are not as tolerant as plastic machined parts.

Looking at design abilities, each medium offers a wide range of capabilities but again, if it’s quality that your project needs, CNC machining is the way to go—3D printed materials are really only suited to personal or home use and injection molded products cannot hold up to the rigors of the aerospace and defense, medical or power and energy industries (among others). Further, machining designs are crafted on the same computer applications that 3D printing uses so there’s no cost associated with changing the design of the product (unlike injection molding, where a new mold would then need to be created).

It is important to note that CNC plastic machining is a specialized craft… not just anyone interested in 3D modeling can create the design for a plastic machined product. Here at AIP Precision Machining, we have over 35 years of technical design expertise and we work diligently with our clients to craft products that exactly meet their project requirements.

If you’re looking to decide on a fabrication process via the material selection available to you, plastics machining offers the widest range of diverse thermoplastics for your project. 3D printing has not advanced its material range in many years and because injection molding requires liquidating its materials, you won’t be able to use the stronger, heat-resistant plastics that might be best for your needs. CNC machining is the only process that allows you to choose from the full assortment of material selections.

3D printing and CNC machining tie for the fastest production times, as both take minutes to complete. Injection molding, however, requires more time to make the mold (which can take weeks to finalize).

Finally, if your project requires the highest levels of tolerance, precision machining produces the most precise and extremely tolerant products. It’s the only fabrication process suited for critical pieces.

Want More Information?

Of 3D printing, injection molding and CNC plastic machining, one process is not necessarily better than the other—it’s dependent on your project requirements. However, plastics machining is by far the most specialized and precise option for high-quality, critical parts needed in industries like aerospace and defense, medical and life sciences and power and energy.

Here at AIP Precision Machining, we commonly craft pieces that are able to survive the rigors of space, the inside of a human body or the corrosive chemicals used on an oil rig. We offer state-of-the-art technology and extensive expertise to provide you with the highest quality products. Contact us to learn more about our process and what CNC plastics machining could do for you.

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Getting Kids Interested in Plastics Manufacturing

July 6, 2017

Kids are hard at work in their plastics manufacturing summer camp.

The word “summer camp” denotes images of canoeing on a lake, staying up late to tell ghost stories or hiking through the woods. But today, that term is expanding to include hardwiring electronics, designing products through CAD and making plastic products kids can take home… Huh?

The plastics manufacturing industry has begun partnering with career centers, schools and summer camps in an attempt to bring attention to manufacturing careers. Camps designed for fifth through twelfth graders are popping up that allow kids to design, build and manufacture plastic projects, giving them an idea of what a job in the plastics industry might be like.

Plastics, like other production sectors, is experiencing a shortage of skilled workers: with only seasoned veterans getting ready to retire and newbies fresh out of school, the generation in-between was steered away from manufacturing jobs by teachers and parents who were concerned the industry was lapsing next to manufacturing giants in China and India. However, the U.S. plastics industry has only continued to grow over the last 25 years… meaning that more and more positions are opening up.

“We want to make sure [students] have an opportunity and some exposure to something like manufacturing,” said Alice Cable, the executive director of Alliance for Working Together—an organization aimed at promoting careers in manufacturing and production. “We also want it to be something that’s fun for them.”

Several camps that are taking off include the Summer Manufacturing Institute, which helps students discover a passion for making things, Penn College’s summer Engineering Camp, which introduces kids to plastics and polymer engineering and Nuts, Bolts & Thingamajigs, which aims to inspire the next generation of manufacturers.

Certainly, it’s been hard work building excitement for the machining trade, but the results are beginning to show; Anne Cowell, an outreach manufacturing educator, notes that these programs are really hooking kids into how cool plastics manufacturing can be: “The students’ energy is contagious as we work through hands-on investigations and they are so engaged in each experiment.”

We’re excited to see what these camps can do for our industry. An influx of youth with a passion for making things is definitely needed and we hope to see some real engagement in plastics manufacturing once these students graduate from high school and college.

Here at AIP Precision Machining, we’re working hard to attract young students to become interested in plastics. If you’d like to learn more about our presence in the community or our manufacturing capabilities, feel free to contact us.

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