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.

 

 

 

 

 

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An Informational Brief on Polymer Machining

 

Vespel Polyimide (PI) is a high-performance polymer frequently machined for end-use in aerospace, semiconductor and transportation technology. This material thrives in extreme environments with high strength, chemical resistance, high temperatures, and a low coefficient of friction. It also has impressive sealing and wear properties.

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

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

 

Machining Thermoplastics vs Thermosets

 

We’ve already said that Vespel 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 Vespel, 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 Vespel in particular? PI is a semi-crystalline engineering thermoplastic, meaning its molecular structure is highly ordered.

 

Properties & Grades of Machined Vespel

 

Combining heat resistance, lubricity, dimensional stability, chemical resistance and creep resistance, Vespel works well in hostile and extreme environmental conditions. Vespel is able to overcome severe sealing and wear. As we mentioned before, these properties allow Vespel to be commonly machined for semiconductors and transportation applications.

Unlike most plastics, Vespel doesn’t produce significant outgassing, even at high temperatures. This makes it useful for lightweight heat shields and crucible support. Vespel also performs well in vacuum applications and extremely low cryogenic temperatures. However, it does absorb a small amount of water, which results in a longer pump time while placed in a vacuum.

Although there are polymers that surpass individual properties of this polyimide, the combination of these factors is Vespel’s primary advantage.

We regularly machine various grades of Vespel at AIP Precision Machining, including the Vespel SP and Vespel SCP family of products from DuPont. The former group is known for their durability and exceptional thermal resistance, while the latter is known for its mechanical properties and thermal stability.

 

Machining Vespel

 

Annealing Vespel

 

The process of annealing and stress-relieving Vespel 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 Vespel

 

Vespel offers ease of machining and tight tolerances due to its inherent mechanical strength, stiffness and dimensional stability. Machining Vespel isn’t too different from machining metals as a result of this; pretend you’re machining brass. Unlike metal, though, Vespel (like all thermoplastics) will deform if you hold it too tightly.

We generally recommend Tungsten Carbide Alloy Tooling, although we recommend diamond tooling for large volume runs or work requiring close tolerances. Be wary of overheating Vespel when you machine it. It shouldn’t become so hot that you can’t grasp it with your bare hands.

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 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.

 

Vespel Machining Guide: Supportive Information

DuPont Machining Vespel Guide

Aerospace Market Materials

Energy Sector Materials

Extreme Performance Materials

 

 

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