Victrex/Tool Gauge to produce aircraft parts using hybrid overmoulding

Tool Gauge, a US manufacturer of plastic and metal assemblies for global aerospace original equipment manufacturers (OEMs), and PEEK/PAEKbased polymer solutions provider Victrex have announced that they will collaborate to develop a new co-moulding technology for the aerospace industry. This new technology will use formed carbon composites combined with carbon filled thermoplastics.

“The aerospace industry continues to increasingly adopt thermoplastic materials as they lower aircraft weight, reduce time and waste from machined metals, and provide sustainable goods for our future,” explains Jim Lee, General Manager of Tool Gauge.

“As part of this collaborative project with Victrex and UW, we aim at replacing machined aluminium components used in commercial aircrafts that are currently expensive and take months to produce with new thermoplastic composite versions,” he explained.

The fabrication of the proposed thermoplastic utilises hybrid overmoulding where thin sheets of carbon fibres are combined with Victrex’s LMPAEK polymer, creating a unidirectional tape.

This material is then stacked and consolidated into one panel with the application of heat and pressure, with small pieces cut from the panel. Finally, the short-fibre reinforced PEEK compound is injection moulded onto the insert. A fusion bond similar to a weld forms between the PEEK compound and LMPAEK composite insert as the molten PEEK melts the surface of the insert. As the part cools, the PEEK compound and LMPAEK composite solidify as one piece.

The hybrid overmoulding process creates a part that is mechanically stronger and stiffer than a part only made with PEEK compound due to the continuous fibre reinforcement used in the composite insert.

The hybrid overmoulding combines injection moulding with thermoforming to create a finished part that is lighter, cheaper, produces less waste, can be produced faster, and has superior fatigue performance.

“As a solution provider, Victrex firmly believes that the path to innovation lies in understanding customers’ needs and pioneering solutions where PEEK and PAEK deliver a strong advantage,” adds Jonathan Sourkes, Head of Market and Business Development for Victrex.

He concludes that through this, the company will continue to be at the forefront of technological advancements.

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