Come See Our New EnduroSharp(R) ABNIR “Fly Away” Compact Surface Prep Kit at MRO Americas

Performance Plastics – Booth 606
MRO Americas – Orlando FL – April 27th thru April 29th

EnduroSharp(R) has changed the way aerospace maintenance professionals remove sealants and adhesives from substrates and fasteners.

EnduroSharp® tools are made from Torlon®, a high strength polymer, creating non-metallic tools that will not damage composite structures during use.

The new, ABNIR “Fly Away” Compact Surface Prep Kit features a selection of commonly used tools with an improved design. Featuring a smaller, compact case, it is easier to store and is an efficient tool kit for aircraft maintenance. The tools are ideal to remove adhesives, sealants and coatings from aircraft structures.

The patented EnduroSharp® lineup consists of a variety of scraper blades, gap blades, reamers, cutter, bits, and discs for removal of substances on aircraft, windmill blades, boat/marine and automotive.

Performance Plastics is a custom precision injection molder of high performance, tight tolerance thermoplastic components. We specialize in geometrically complex precision parts that consist of chemically inert materials. Our expertise led to the development of our patented EnduroSharp® line of Aircraft Maintenance Tools.

For more information on the Enhanced EnduroSharp® Pocket Handle, or any of our EnduroSharp® product line, please contact Rich Reed at rreed@performanceplastics.com or our website at www.performanceplastics.com.

  • New Torlon(R) Nonmetallic Tools
  • Under contract with the Air Force Research Laboratory’s Materials
    Integrity Branch (AFRL/RXSA), the University of Dayton Research
    Institute (UDRI) developed improved material removal tools & accessories
  • Transitioning developed tools to multiple weapons systems for material
    removal applications on composite components
  • Injection molded from Torlon® 5030 – Solvay’s polyamide-imide (PAI) resin
    30% glass reinforced plastic
  • Commercially available from Performance Plastics (Cincinnati, OH)
    • EnduroSharp™ trade name

Overview-of-EnduroSharp™-Nonmetallic-Torlon®-Aircraft-Maintenance-Tools-Presentation

 

The lack of reliable and effective nonmetallic material removal tools available to maintainers
drives the continued use of unapproved tools and/or methods when removing materials from
aerospace vehicles. The use of metallic tools has resulted in damage to vehicles, both short term
and long term, causing the need for expensive repairs and reduction in vehicle availability.
The University of Dayton Research Institute under contract to the Air Force Research Laboratory
has developed and commercialized a series of nonmetallic material removal tools under the
“EnduroSharp” trademark manufactured from glass-filled Torlon thermoplastic produced by
Solvay Engineered Plastics. The use of this material coupled with the tools’ designs is
responsible for their superior stiffness and durability (resistance to chemicals and heat) and
enhance the tools’ ability to maintain sharp cutting edges, allowing efficient removal of coatings,
boots, tapes, sealants, gap fillers and caulking materials, pressure , sensitive adhesive (PSA), and
tape residue without damaging underlying composite surfaces.

EnduroSharp™-Nonmetallic-Torlon®-Aircraft-Maintenance-Tools-Abstract

 

 

Nutplates fail for a variety of reasons

  • Poor surface prep
  • Wrong grip length fastener (too long) when engaged pushing nutplate off structure
  • Fastener locked up in nut element (i.e. not turning) due to excessive heat from fastener during installation
  • Improper fastener torque sequencing for panel installation

Following aircraft specific T.O. – takes from 24 to 72 hours to effect a repair

Removal-and-Replacement-of-Failed-Bonded-Nutplates-Presentation

 

The lack of reliable and effective nonmetallic material removal tools available to maintainers
drives the continued use of unapproved tools and/or methods when removing materials from
aerospace vehicles. The use of metallic tools has resulted in damage to vehicles, both short term
and long term, causing the need for expensive repairs and reduction in vehicle availability.
The University of Dayton Research Institute under contract to the Air Force Research Laboratory
has developed and commercialized a series of nonmetallic material removal tools under the
“EnduroSharp” trademark manufactured from glass-filled Torlon thermoplastic produced by
Solvay Engineered Plastics. The use of this material coupled with the tools’ designs is
responsible for their superior stiffness and durability (resistance to chemicals and heat) and
enhance the tools’ ability to maintain sharp cutting edges, allowing efficient removal of coatings,
boots, tapes, sealants, gap fillers and caulking materials, pressure sensitive adhesive (PSA), and

tape residue without damaging underlying composite surfaces.

 

EnduroSharp™-Nonmetallic-Torlon®-Aircraft-Maintenance-Tools-Abstract

Computed Tomography Measures Tighter Tolerances

Metrology News

 

 

 

 

 

 

 

 

Plastic injection molding continues to become more and more sophisticated with part tolerances becoming tighter and tighter. Initially, tight tolerance was defined as +/-.002 inches (0.0508 mm) and a very tight tolerance is +/-.001 inches (0.0254 mm) But today there are many factors that impact tight tolerance including part complexity and size, resin selection, tooling, and process conditions. So, getting the mold, part design, material selection and process correct is crucial when working with a product that requires tight tolerances.

Tight tolerances are essential when manufacturing complex parts, especially in the aerospace & defense, medical & life sciences, and diversified industrial sectors.  A few thousandths of an inch can be the difference between a component that fits and one that does not – if tight tolerances are not achieved properly the resulting products may underperform. So, it is critical that clients understand tight tolerances and their underlying objectives. Performance Plastics has parts in production that are +/-.0004 inches (0.01016 mm). Parts are measured in their Metrology lab with a CT Scanner. Engineers use Zeiss metrology equipment to analyze every aspect of parts and the problem at hand, not just the data on the part dimensions and the dimensional tolerances.

Benefits of Tight Tolerances

There are many benefits to manufacturing parts with tight tolerances. It ensures that parts work together smoothly and fit as intended in their final form; parts mesh well and deliver enhanced functionality.   They produce lower failure rates and result in higher client satisfaction. Tight tolerances can also result in fewer post-molding processing requirements.  Additionally, tight tolerances allow for parts to be transitioned from metal to plastic, reducing overall weight and cost of the final product. This can be very advantageous in some industries, such as aerospace and defense.

Design for Tight Tolerances

Not every plastic injection molding project requires tight tolerances, and some organizations insist on tight tolerances for non-critical features.  Tight tolerance should only be required in instances where they are critical.  Many products require standard tolerancing because the consequences of failure are low.  As a general rule, designers should keep tolerances as large as possible while maintaining the desired functionality of the part.

Materials for Tight Tolerances

Additionally, material selection is a critical element in achieving tight tolerances.  Certain resins perform better under certain circumstances.  An experienced design engineer can guide a client in choosing the most affordable material that will deliver the best result.  So, it’s critical to bring in an experienced team early in the design process.

By engaging a production team during the design phase, part functionality, material selection and design can be discussed upfront, and the team can jointly develop a manufacturing process and correct materials that will produce high-precision components. It is crucial for organizations to partner with an experienced injection molder, who has expertise; the design and manufacturing teams should be integrated to allow manufacturability issues to be identified and addressed during the design process – thus saving significant time and unnecessary cost.

Establishing the right process and correct materials for each product and developing repeatability are key to manufacturing tight tolerance parts. While every application is different, there are some process and material conditions that impact tolerances. For example, quick cavity filling and uniform cooling at the desired temperature are conditions that are crucial to achieving repeatability, and thus, parts with tight tolerances.

 

Posted from Metrology News – April 8, 2021

Plastic injection molding continues to become more and more sophisticated with part tolerances becoming tighter and tighter. Initially, tight tolerance was defined as +/-.002 inches and a very tight tolerance is +/-.001 inches. But today there are many factors that impact tight tolerance including part complexity and size, resin selection, tooling, and process conditions. So, getting the mold, part design, material selection and process correct is crucial when working with a product that requires tight tolerances.

Tight tolerances are essential when manufacturing complex parts, especially in the aerospace & defense, medical & life sciences, and diversified industrial sectors.  A few thousandths of an inch can be the difference between a component that fits and one that does not – if tight tolerances are not achieved properly the resulting products may underperform. So, it is critical that clients understand tight tolerances and their underlying objectives. Performance Plastics has parts in production that are +/-.0004 inches. Parts are measured in their Metrology lab with a CT Scanner.

 

Benefits of Tight Tolerances

There are many benefits to manufacturing parts with tight tolerances. It ensures that parts work together smoothly and fit as intended in their final form; parts mesh well and deliver enhanced functionality.   They produce lower failure rates and result in higher client satisfaction. Tight tolerances can also result in fewer post-molding processing requirements.  Additionally, tight tolerances allow for parts to be transitioned from metal to plastic, reducing overall weight and cost of the final product. This can be very advantageous in some industries, such as aerospace and defense.

Design for Tight Tolerances

Not every plastic injection molding project requires tight tolerances, and some organizations insist on tight tolerances for non-critical features.  Tight tolerance should only be required in instances where they are critical.  Many products require standard tolerancing because the consequences of failure are low.  As a general rule, designers should keep tolerances as large as possible while maintaining the desired functionality of the part.

Materials for Tight Tolerances

Additionally, material selection is a critical element in achieving tight tolerances.  Certain resins perform better under certain circumstances.  An experienced design engineer can guide a client in choosing the most affordable material that will deliver the best result.  So, it’s critical to bring in an experienced team early in the design process.

By engaging a production team during the design phase, part functionality, material selection and design can be discussed upfront, and the team can jointly develop a manufacturing process and correct materials that will produce high-precision components. It is crucial for organizations to partner with an experienced injection molder, who has expertise; the design and manufacturing teams should be integrated to allow manufacturability issues to be identified and addressed during the design process – thus saving significant time and unnecessary cost.

Establishing the right process and correct materials for each product and developing repeatability are key to manufacturing tight tolerance parts. While every application is different, there are some process and material conditions that impact tolerances. For example, quick cavity filling and uniform cooling at the desired temperature are conditions that are crucial to achieving repeatability, and thus, parts with tight tolerances.

Performance Plastics is highly skilled at designing and molding using high performance materials such as PEI-Ultem®, PAI-Torlon®, Ryton® PPS Plastic, PEEK, and Fluoropolymers such as FEP, PFA, and PVDF.  We work with our customers to solve technically challenging problems.   We can propose materials to implement part functionality in the design stage of development. We offer manufacturing solutions such as a clean room, the ability to offer direct gating of fluoropolymers, high volume production, visual inspection, and automated facilities.

For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email rreed@performanceplastics.com

 

 

For decades, maintenance personnel have searched for a non-metallic scraper tools or sealant remover tools that could hold an effective edge, but not damage aircraft structures, like composite and aluminum.

That’s why Performance Plastics created the patented EnduroSharp® line of Torlon® Maintenance Tools. Suitable for aircraft, automotive, marine and windmill structures, these nonmetallic scraper tools hold a superior edge and are extremely durable for removing sealants, adhesives, and coatings. What’s more, maintenance personnel no longer have to resort to sharpened putty knives, scribes, and utility blades.

EnduroSharp® is pleased to announce our new and improved Nutplate Abrasion Tool (NAT).  An alternative to traditional abrasion methods, this tool was specifically designed to allow maintainers to quickly abrade the bond surface of CR series nutplates. The tools radially abrade the bond surface of the nutplate, ensuring that 100% of the bond surface is abraded uniformly in a manner of minutes.

The NAT kit consists of six components:

  • One each upper handle (top)
  • One each lower handle (base)
  • Four each nutplate base inserts

The NAT kit is available with a convenient carrying case.  The rugged case comes with a high-density custom foam insert for easy inventory and protection.

For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email rreed@performanceplastics.com