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Victrex carbon fiber composites reduce airline fuel costs

18 Mar '13

3 min read

With the aerospace industry focusing on reducing aircraft weight and lean manufacturing, engineers are searching for reliable solutions such as thermoplastic composites that can perform with at least the same assurance as traditional metals and thermosets. In response to these requirements, Tri-Mack Plastics Manufacturing Corporation, a molder of high temperature engineering thermoplastics located in Bristol, Rhode Island, has developed VICTREX PEEK composite manufacturing capabilities and produced brackets for use in aircraft structural applications. As VICTREX PEEK polymers have been used in injection molded aerospace components for more than 25 years, Tri-Mack specified the material due to its excellent technical features and proven track record in the industry.

Based on current fuel prices and studies, the removal of 1 kilogram (2.2 pounds) of weight from a short-range aircraft can save airlines up to $100 in annual fuel costs. “Assuming that the composite brackets can remove 100 kilograms (220.5 pounds) of weight, an airline with 500 short-range aircraft could save up to $5 million per year in fuel costs by making the switch from metal,” explained Ralf Weidig, Composites Business Leader for Victrex.

Besides up to 70% weight savings compared to metals such as stainless steel, aluminum, and titanium, the innovative composite manufacturing process used by Tri-Mack provides several benefits leading to faster part manufacturing cycle times compared to thermosets. “Thermoset composite parts typically take several hours to complete,” said Tom Kneath, Director of Sales and Marketing at Tri-Mack. “The VICTREX PEEK thermoplastic composite brackets have manufacturing cycle times measured in minutes. That speed, paired with the ability to recycle the material for other applications, takes us to a whole new level of processing efficiency that isn't achievable with thermosets.”

Component integrity is also critical to keeping aircraft in service in order to minimize maintenance and downtime. Thermoplastic composites made from VICTREX PEEK can provide the chemical and corrosion resistance to jet fuel, hydraulic fluid, de-icing solution, salt, steam, water and other commonly used service fluids that would typically undermine the longevity of metals. “VICTREX PEEK composites can offer between four and five times higher fatigue strength, specific stiffness, and specific strength when compared to traditional metals such as aluminum,” said Weidig. “These mechanical properties along with vibration and noise dampening improvements make VICTREX PEEK composites an attractive and viable solution for engineers looking to replace heavy metals and thermosets.”

About Tri-Mack Plastics Manufacturing Corporation
Tri-Mack Plastics Manufacturing Corporation is an innovative engineering and manufacturing company specializing in high temperature thermoplastics and thermoplastic composites. For more than 35 years, customers have relied on Tri-Mack to identify the best material, part design, and manufacturing process. Engineering expertise and cutting-edge technology enable Tri-Mack to support projects from initial concept to commercial production.

Tri-Mack provides unparalleled service and high quality processing capabilities including machining, injection molding, assembly, and composite manufacturing for the aerospace, medical, electronics, industrial, and chemical processing markets. Tri-Mack is IS0 9001:2008 and AS 9100 certified.

Tri-Mack Plastics Manufacturing Corporation

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Victrex carbon fiber composites reduce airline fuel costs

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