EnduroSharp® has changed the way aerospace maintenance professionals remove sealants and adhesives from substrates and fasteners. EnduroSharp® resharpenable tools are made from Torlon®, a high strength polymer, creating a non-metallic blade tool that will not damage composite structures during use.

The lack of reliable and effective nonmetallic material removal tools available to maintainers drove the continued use of unapproved tools and/or methods for 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.

Because of this need, The University of Dayton Research Institute under contract to the Air Force Research Laboratory developed a series of nonmetallic material removal tools under the “EnduroSharp” trademark manufactured from Torlon thermoplastic manufactured by Solvay Engineered Plastics and produced by Performance Plastics of Cincinnati OH.

Attached is the published white paper outlining the development of the “EnduroSharp®” line of Torlon® non-metallic aircraft maintenance tools.  In this paper you will find:

  • Abstract
  • Background
  • Prototype Development Path
    • Gap Filler Removal Bits
    • Torlon Scraper Blades
    • Torlon Gap Blades
  • Results
  • Conclusions

To review the white paper in full, please click here.

EnduroSharp® Products are currently approved for use by numerous governmental and corporate defense organizations including the USAF, USMC, USN, USCG, Lockheed Martin, Boeing, and Dassault.

EnduroSharp® Products are now available as individual components, tools and consumables or as Aviation Kits.

For more information on the EnduroSharp® line or Torlon® Aircraft Maintenance Tools, please contact our Vice President of Sales and Marketing, at (513) 321-8404 or visit our website at www.performanceplastics.com/endurosharp.

 

Medical devices must be dependable and safe, and moving operations back to the United States allow companies to have better control over the entire operation – procurement, engineering, production, and distribution.  The result is a higher standard of quality in products.  Medical device companies and other advanced industries need to have extensive and precise control over the entire supply chain of their products.

As an American small business, Performance Plastics is pleased to see the trend of manufacturing operations moving back to the United States.  A range of economic and strategic factors due to the recent epidemic have tipped the scales exponentially since 2020.

While there are many benefits of reshoring, some of the most important reasons include:

  • Greater Control of Supply Chain

Getting all your moving pieces to work seamlessly can be a near impossible task, especially across language and time zone barriers.  One of the primary advantages of reshoring is that it allows you to tighten your supply chain.

  • Reduced Lead Times

The greater the distance between where your device is manufactured and where you are located, the longer you can expect your lead time to be.  However, distance is not the only factor.  When moving from one country to another, inspection and transportation times between countries can add up to 50% to your lead time.

  • Fewer Import Tariffs

Import tariffs vary from administration to administration, but they will always be in place.  The recent increase in tariffs have caused the cost advantages of manufacturing offshore to shrink.

  • Reduced Energy Costs

Recent changes to international gas and power prices have drastically increased the prices of manufacturing and transportation from other countries.  Impact on the environment and achieving higher sustainability are very important to consumers.

  • Potential to Improve Brand Perception

Although we live in an international community, the origin of a product still has an impact on the perception of quality.  Some lower cost manufacturing countries even have a perception of being “dangerous”.

Medical devices necessitate the highest quality standards possible, which can’t always be regulated in an offshore manufacturing environment.  The vast global, economic, legal and social changes are all very dynamic and unpredictable in nature – making relocating operations a more sustainable, stable and efficient choice.

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics for medical device components. Our proprietary tool design software, processes and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds.

For more information on Performance Plastic’s capabilities, please contact Rich Reed, Vice President of Sales, and Marketing at 513.321.8404 or email at rreed@performanceplastics.com 

 

 

EnduroSharp(R) Gap Blades & Adapter

EnduroSharp® has changed the way aerospace maintenance professionals remove sealants and adhesives from substrates and fasteners. EnduroSharp® resharpenable tools are made from Torlon®, a high strength polymer, creating a non-metallic blade tool that will not damage composite structures during use.

Scraper blades are designed for use in larger areas where a large quantity of material needs to be removed. Made from a non-marring Torlon® material the blades are a quick, safe and effective method of removing sealants and adhesives from composite structures.

Gap blades are designed for use in smaller grooves and channels where scraper blades are too large.  With a multi head edge, gap blades offer the ability to eliminate materials from multiple surfaces of the seam.

Technicians often use a scraper blade in applications where a gap blade will deliver a quicker, cleaner result.  While the scraper blade offers one cutting edge, the gap blades offer three, allowing the removal of sealants and adhesives from the surfaces more completely.                                                   

The tools are designed to complement each other.  By using an adapter tool, both the scraper blades and gap blades can be used with the same handle.  This provides the technician the ability to switch the blades based on the progression in the removal process.

Using the adapter also allows for the application of flexible incremental skiving techniques when removing sealants and adhesives.  Incremental skiving involves the technique of removing subsequent thin layers of material to achieve a cleaner finish.  The technician can switch back and forth between the blades as needed.

The EnduroSharp® scraper and gap blades are just a few of the many products offered in the EnduroSharp® Product line. Contact Rich Reed for our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com, more information on our EnduroSharp® kits and products.

 

 

 

 

 

 

 

Ultem Polyetherimide is a material widely used in industrial applications.  It is an amorphous material with exceptional strength, flame resistance and generates very low levels of smoke. It is often used in the production of circuit boards, sterilization equipment, battery components and oil and gas equipment,

ULTEM is commonly used in industrial applications needing a durable, high-performance, cost-effective alternative to metal: strong enough to replace steel in some applications and light enough to replace aluminum in others.   It outperforms comparable thermoplastics when it comes to resisting creep and does not degrade under repeated mechanical stress. It also holds up well when brought into contact with various fuels, coolants, and lubricants

ULTEM has one of the highest dielectric strengths of any thermoplastic material. It works very efficiently as an electrical insulator. ULTEM also has one of the lowest rates of thermal conductivity, allowing parts machined from ULTEM to act as thermal insulators. ULTEM offers excellent long-term heat resistance with its mechanical and physical properties remaining stable at elevated temperatures.  Unlike most other amorphous plastics, ULTEM resins retain strength and resist strength cracking when exposed to environmental stresses.

Ultem is now widely used in:

  • Automotive
  • Semiconductor
  • Telecom Components
  • Molded Interconnect Devices
  • HVAC/Fluid Handling Devices
  • Oil & Gas Applications

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics. Ultem® is an amorphous material, which can cause complications during the injection molding process. A specific set of conditions, equipment, and processing procedures must be followed to effectively injection mold Ultem®. Our proprietary tool design software, processes and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds.

Ultem® is one of the many high-performance polymers in which Performance Plastics specializes.  For more information on Performance Plastic’s capabilities, please contact Rich Reed, Vice President of Sales and Marketing at 513.321.8404 or email at rreed@performanceplastics.com.

Diabetes care has seen several innovations through the years. One of the most important developments is the insulin pump, which for many patients provides an option to the traditional needle and syringe approach to insulin injections. Insulin pumps are small, computerized devices that are about the size of a small cell phone.  Insulin pumps deliver doses of insulin, the hormone that regulates blood sugar, on a pre-programmed schedule.

High performance polymers have enabled medical device manufacturers to go beyond the functionality of ordinary plastic materials to develop innovative devices for treating diabetic patients.  Resins such as FEP and PFA fluoropolymers are chemically resistant resin with outstanding properties and are currently used in numerous healthcare applications. Physical properties of resins such as high tensile strength, dimensional stability, excellent friction and wear characteristics and the ability to replicate fine features are important advantages as parts become smaller and thinner.

In developing new and advanced insulin delivery devices, resins offer unique advantages and have expanded the possibilities for innovative design and manufacturing. Medical grade fluoropolymers, such as FEP and PFA allow for the miniaturization of device components without the constraints of glass or ordinary plastic materials. With these capabilities, designers can now expand design performance and possibilities. Fine detail replication resulting from the material’s high flow and excellent dimensional stability properties position resins as an excellent material for lightweight and compact precision delivery devices.

Device components such as insulin storage require the use of a proven polymer materials. In addition to compatibility with insulin, purity and very low levels of leaching, resins provide excellent moisture barriers and extremely low water absorption, both necessary properties for optimal long-term drug container storage. These resins are also FDA approved and are compatible with all conventional sterilization methods from gamma to steam.

In future insulin delivery systems, the use of FEP and PFA resin components for various parts of the device will continue to rise. With the advantages engineering polymers offer for design innovation and performance, resins will continue to be the material of choice for delivery applications.

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics. Our proprietary tool design software, processes and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds. For more information on Performance Plastic’s capabilities, please contact Rich Reed, Vice President of Sales, and Marketing at 513.321.8404 or email at rreed@performanceplastics.com.

 

 

PFA plastic (Fluoropolymer) Thermoplastic Components

EnduroSharp® 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 a non-metallic scraper tool that will not damage composite structures during use. The EnduroSharp® lineup consists of a variety of scraper blades, gap blades, reamers, cutter, bits, and discs for removal of adhesives on aircrafts. The product line even consists of kits containing all of the parts and sizes that you will need.

The EnduroSharp® Scraper Blade & Holder Kit is one of the most popular kits ordered. This kit includes the standard scraper blade holder, pocket scraper blade holder, and 2 scraper blades of each size. EnduroSharp® Torlon® Scraper Blade (TSB) inserts come in 5 different sizes, TSB-170, TSB-230, TSB-500, TSB-750, and TSB-1200. The blades slide and lock into the detent pin of the standard scraper blade holder handle, to easily alternate between the sizes as needed. This kit also contains the pocket scraper blade holder for use of the scraper blades in smaller areas.

The EnduroSharp® Scraper Blade & Holder kit is just one of the kits offered in the EnduroSharp® Product line. Contact Rich Reed for our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com, more information on our EnduroSharp® kits and products.

 

 

Ultem PEI Polyetherimide thermoplastic component

Ultem Polyetherimide is a material widely used in the aerospace industry.  It is often applied to aircraft components for weight reduction in place of metal parts.  Additionally, since it has a high thermal resistance rating, polymer components have the benefit of evading radar detection in military aircraft.

ULTEM is among the few resins approved for use in the aerospace sector. It outperforms comparable thermoplastics when it comes to resisting creep and does not degrade under repeated mechanical stress. It also holds up well when brought into contact with various fuels, coolants, and lubricants. Its flame-resistance ensures that it meets FAA regulations for flammability.

ULTEM has one of the highest dielectric strengths of any thermoplastic material. It works very efficiently as an electrical insulator. ULTEM also has one of the lowest rates of thermal conductivity, allowing parts machined from ULTEM to act as thermal insulators. ULTEM offers excellent long-term heat resistance with its mechanical and physical properties remaining stable at elevated temperatures.  It is also flame resistant with extremely low smoke generation. ULTEM is FDA and NSF approved for both food and medical contact resistance act and therefore is an excellent choice for aircraft galley equipment such as ovens, microwaves and hot or cold beverage dispensing systems.

Ultem is now widely used in:

  • Personal Service Units
  • Oxygen Panels
  • Ventilation Systems
  • Connectors
  • Cable Ducts
  • Latches
  • Hinges
  • Food Tray Containers
  • Door Handles
  • Interior Cladding Parts

Ultem offers exceptional balance of flame retardancy, low smoke emission and low smoke toxicity making it an excellent candidate for aerospace and aircraft applications.

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics. Ultem® is an amorphous material, which can cause complications during the injection molding process. A specific set of conditions, equipment, and processing procedures must be followed to effectively injection mold Ultem®. Our proprietary tool design software, processes and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds.

Ultem® is one of the many high-performance polymers in which Performance Plastics specializes.  For more information on Performance Plastic’s capabilities, please contact Rich Reed, Vice President of Sales and Marketing at 513.321.8404 or email at rreed@performanceplastics.com