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-PEIULTEM 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 - PBICELAZOLE 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

 

DURATRON PILike 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

 

TORLONDURATRON 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

 

TECHTRONTECHTRON 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

 

RADELWith 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-FKel-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

 

PEEKPEEK 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

 

KYNAR - PVDFAnother 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.

 

 

 

 

 

Click here to search our material data for more information or request a quote here.

 

 

Follow AIP Precision Machining on Linkedin

linkedin logo

An Informational Brief on Polymer Machining

 

Among the many plastics AIP precision machines, PSU (Polysulfone) is a high-performance thermoplastic made from UDEL Resin.  This particular thermoplastic is able to retain its properties in temperatures ranging from -150°F (-100°C) to 300°F (150°C).  This precision machined plastic also has excellent radiation stability, chemical resistance as well as hydrolysis resistance for continuous use in hot water and steam.

 

In many applications, PSU is used over stainless steel parts or aluminum as the material is seven times lighter than stainless steel and can also be steam-cleaned in areas like chemical labs.  For this reason, it has a wide range of uses in the following industries:  aerospace and defense, medical and life sciences as well as specialized industrial applications.

 

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

 

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

 

Machining Thermoplastics vs Thermosets

 

We’ve already said that PSU 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 PSU, 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.

 

The table below outlines the main properties of thermoplastics versus thermosets:

 

Thermoplastics

Thermosets

  • Good Resistance to Creep
  • Soluble in Certain Solvents
  • Swell in Presence of Certain Solvents
  • Allows for Plastic Deformation when Heated
  • High Resistance to Creep
  • Insoluble
  • Rarely Swell in Presence of Solvents
  • Cannot Melt

 

From there, thermoplastics are categorized into amorphous or crystalline polymers per the figure below:

 

Source: https://www.ejbplastics.com
 

Based off of the chart, PSU is an amorphous, high performance engineering thermoplastic, meaning its molecular structure is randomly formed.  The result is that amorphous materials soften gradually with temperature increase, making them easy to thermoform.

 

Properties of PSU (Polysulfone)

 

Amorphous thermoplastics are usually translucent in color, but the gradients vary.  PSU, for instance, is amber semi-transparent.

 

Since they are isotropic in flow, they have better dimensional stability than semi-crystalline plastics and are less likely to warp.  Thermoplastics like PSU offer superior impact strength and are best used for structural applications.

 

The materials bond well using adhesives. They also tend to offer excellent resistance to hot water and steam, good chemical resistance, stiffness and strength. PSU and PEI are especially good examples of amorphous thermoplastics offering these qualities.

 

Machining PSU (Polysulfone)

 

Annealing PSU

 

Like many amorphous thermoplastics, PSU is especially sensitive to stress-cracking, so stress-relieving through an annealing process is highly recommended before machining.  Annealing PSU 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.  AIP uses computer controlled annealing ovens for the highest quality precision machining of PSU and other thermoplastics.

 

Machining PSU

 

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 PSU. 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 only machines polymers.

 

Preventing Contamination

 

Contamination is a serious concern when machining polymer components for technically demanding industries such as aerospace 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.  This allows us to de-risk the process from metallic cross contamination.

 

PSU (Polysulfone) Machining Guide Supportive Information

Amorphous Materials Guide

 

Explore Our Inventory

or request a quote here.

Follow AIP Precision Machining on Linkedin

linkedin logo