Overview of EnduroSharp™ Nonmetallic (Torlon®) Aircraft Maintenance Tools Presentation

April 13, 2021  |  , , ,
  • 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

 

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EnduroSharp(R) Nonmetallic (Torlon)(R) Aircraft Maintenance Tools Abstract

April 13, 2021  |  , , ,

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

 

 

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Removal and Replacement of Failed Bonded Nutplates Presentation

April 13, 2021  |  , , ,

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

 

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Removal and Replacement of Failed Bonded Nutplates Utilizing Nonmetallic Torlon® Adhesive Cutters Whitepaper

April 13, 2021  |  , , ,

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

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Introducing the EnduroSharp® ABNIR “Fly Away” Compact Surface Prep Kit

January 20, 2021  |  ,

 

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 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 [email protected] or our website at www.performanceplastics.com.

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EnduroSharp® Torlon® Maintenance Tools For Aircraft and Windmill Blades

January 6, 2021  |  ,

EnduroSharp® has changed the way maintenance professionals remove sealants and adhesives from composite substrates and fasteners. EnduroSharp® tools are made from Torlon®, a high strength, high performance plastic polymer which provides all the benefits of a sharp tool without the risk associated with caustic devices.

EnduroSharp® Torlon® maintenance tools are non metallic scraper tools designed to hold a superior edge but not damage composite structures like aluminum, fiberglass and carbon fibers. Constructed from a custom polyamidimide blend (PAI), they are durable, nonmetallic blades designed to remove elastomeric coatings, protective boots, tapes, sealants and adhesive residue and gap filler materials.

Composite materials are made of two or more materials with different physical or chemical properties that when combined, do not fully blend but together become stronger and more durable.  Materials used in composites include resins of glass fiber, reinforced polyester, reinforced epoxy, carbon fibers, graphite and blends of metals. Combining the materials produce components that are strong, lightweight, corrosion resistant and dimensionally stable.  They feature high rigidity and resistance to to torsion and fatigue with good flexibility, corrosion resistant and reduced weight.

EnduroSharp® is an improvement over existing nonmetallic scrapers due to the Torlon® stiffness and edge design.  Torlon® holds the cutting longer, is easier to sharpen and is machinable to configure. Torlon® is a high strength, high temperature polymer that is injection molded and oven “cured” to produce the highest tensile strength.  It posses features that are ideal in that they hold an effective,  resharpenable edge but not pose a threat to composite structures   It is an easy to use, will less effort for tough materials and deeper gaps.  The tool is ideal for tighter edges, and is designed to remove adhesives, sealants and coatings from low weight, design flexible structures.

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

Performance Plastics is a custom injection molder of high performance, tight tolerance thermoplastic components.  We specialize in geometrically complex precision parts that consist of chemically inert materials.

For more information on the EnduroSharp® product line, please contact Rich Reed at [email protected] or our website at www.performanceplastics.com

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Introducing our Improved EnduroSharp® Nutplate Abrasion Tool

November 10, 2020  |  , ,

 

 

Introducing the EnduroSharp® Nutplate Abrasion Tool “The NAT”. The NAT consists of six components 1 each upper handle (top), 1 each lower handle (base) and 4 each nutplate base inserts.

The NAT along with the specially designed abrasive pads (sold separately) allows the maintainer to quickly abrade the bond surface of CR series nutplates.  The tools radially abrades the bond surface of the nutplate, ensuring that 100% of bond surface is abraded uniformly in a matter of minutes.

The NAT is available with or without a convenient carrying case. The rugged case comes with a high-density custom foam insert for easy inventory and protection.

NAT “CR Series” Abrasive Pads

 

Nutplate Abrasion Tool (NAT) Operational Flow Chart

 

 

 

Nutplate Abrasion Tool (NAT) Instructions

A.  Select the appropriate unused abrasive pad that matches the nutplate being installed.

B.  Align flats on an unused abrasive pad with the flats and detent pins in the NAT upper handle (top) and snap into place.

C.  Ensure abrasive pad is fully seated in the top portion of the NAT.

D.  Align and snap the NAT nutplate insert that matches the size of the nutplate being installed into the NAT lower handle (base).

E.  Solvent wipe the nutplate being installed with the appropriate solvent and AMS3819 wipes.

F.  Seat nutplate into the cavity of the nutplate insert

G.  Align NAT top with base, press together, feeding the nutplate fixture through the hole in the abrasive pad and seat the nutplate bond surface to be abraded against the abrasive pad.

H.  Oscillate the abrasive pad back and forth 15 times by rotating the NAT top and base back in opposite directions

I.  Separate the NAT top from the base

J.  Inspect nutplate bond surface for uniform abrasion (Do not touch, wipe or clean the abraded surface). Reseat nutplate in the NAT nutplate insert and measure the abraded nutplate surface with the Surface Analyst (SA reading less than 50 is required). Re-abrade if necessary.

K.  Discard the used abrasive pad.

L.  Apply appropriate adhesive to nutplate bond surface and install in structure per Technical Data or manufactures directions.

 

 

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Introducing the Enhanced EnduroSharp® Pocket Handle

November 4, 2020  |  ,

 

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 aircraft composite structures during use.

The new, Enhanced EnduroSharp® Pocket Handle features a heavier, ergonomically improved design.  It is easier to use and is a more effective tool for aircraft maintenance.  The tool is ideal for tighter edges, and is designed to remove adhesives, sealants and coatings from aircraft structures.

The EnduroSharp® lineup consists of a variety of scraper blades, gap blades, reamers, cutter, bits, and discs for removal of substances on aircrafts.

Performance Plastics is a custom 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 [email protected] or our website at www.performanceplastics.com.

 

 

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EnduroSharp® Is Improving Aircraft Maintenance

August 4, 2020  |  , ,

The aerospace industry has seen a lot of change this year. Effects of Covid-19 keeping planes on the ground and the push to move to a zero-waste philosophy has created a new perspective. The need to watch budgets and recycle all parts of the plane has become a greater priority. This change is increasing aircraft maintainers need for non-marring aircraft maintenance tools.

Non-marring aircraft maintenance tools allow maintainers to effectively remove adhesives, sealants, and coatings with out causing damage to the aircraft structure. Decreasing damage to the aircraft structure during maintenance work will cause for the aircraft structure to last longer. Increasing the life of an aircraft structure and decreasing the time a maintainer spends on the structure is the goal for aircraft maintainers. Non-marring products, such as EnduroSharp® are improving aircraft maintenance.

Our EnduroSharp® product line consists of an array of non-marring aircraft maintenance tools. Each tool has been precisely designed and tested by  maintainers to create the most effective adhesive removal products in the market. The nonmetallic tools are made from Torlon®, a high-performance plastic, creating an extremely durable tool that will hold superior edge while removing adhesives and sealants.

“In more than 25 years of aircraft maintenance experience in removing sealants, adhesives, and coatings I have never found a non-metallic hand scraper tool that holds up to the use. The EnduroSharp® Torlon® scraper blades not only hold a superior edge but are extremely durable. These scraper blades change the game in coating removal!” -F-35 Joint Strike Fighter Maintainer

To learn more about our EnduroSharp® product line contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected].

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Product Spotlight – EnduroSharp® Deluxe Scraper Blade & Holder Kit

July 22, 2020  |  ,

The product line for 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® Deluxe Scraper Blade & Holder Kit is the most popular kits ordered. This kit includes the EnduroSharp® pneumatic tool, 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 pneumatic tool or 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® Deluxe 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 [email protected], more information on our EnduroSharp® kits and products.

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