5 STEPS FOR SUCCESS IN AEROSPACE PLASTIC PART MANUFACTURING

At Controlled Fluidics, we're dedicated to ensuring that manufacturing aerospace plastic components is as straightforward and efficient as possible. We're here to offer our expertise and support every step of the way. However, successful projects are a team effort, and much depends on the aerospace engineers we work with being ready to engage in a collaborative process.

We've laid out a clear 5-step guide to create the best components and systems for those in the aerospace industry. By following this guide, you can combine engineering excellence with manufacturing precision to achieve outstanding results in your aerospace projects.

Step 1: Design with Manufacturability in Mind

The design phase is the foundation of efficient manufacturing. Aerospace engineers must consider not only the function and performance of the part within a system, but also how it will be manufactured. This includes:

Material Selection:

When choosing materials for aerospace parts, you need to think about the temperatures your part will face. Make sure the material can handle the expected operating temperature range it might see in use. For example, materials like PEEK, PPS, and polyimides are good for hot conditions, but they're all a bit different in terms of other properties. Pick one that matches your part's temperature needs. Also, check how well the material handles heat flow — you want to make sure it can manage the heat properly.

Tolerances:

In the aerospace industry, tolerances are especially tight, often down to a few micrometers. For a bit of context, consider that a typical human hair is about 70 micrometers thick, so we're working with margins that are finer than a strand of hair. To achieve this level of precision, it's essential to understand plastic manufacturing capabilities and set realistic tolerances that consider the material’s properties and the part's intended use. By setting tolerances that reflect both the material's characteristics and the manufacturing process's precision capability, you can avoid the aerodynamic and structural issues that may arise from even the smallest miscalculations.

Geometries:

Creating aerospace parts requires smart design to keep things both functional and manufacturable. To do this, start by stripping back the design to remove any unnecessary complexity that could make manufacturing harder and more expensive. Keep the essential features that the part needs to work properly but try to use simpler shapes and standard sizes where you can.

Remember that the more material you need to cut away to create your part, the longer and more costly it will be to make. For complex parts, think about breaking them down into smaller, simpler pieces that can be made separately and put together later. This can save time and money in manufacturing and make repairs easier down the line.

Step 2: Utilize Digital Tools and Prototyping

Digital tools and prototyping are crucial to bridge the gap between a design concept and a functional part. By using these techniques, the manufacturer can ensure each component is designed and tested for peak performance before production begins. We have two suggestions below.

CAD Models:

CAD models are the blueprints of aerospace parts. They allow the manufacturer to create a detailed 3D design that can be inspected and tweaked with precision. This digital stage helps them spot any design issues that could become problematic later on. It's like a trial run for the part. You can make all the necessary adjustments in the virtual world, which is faster and cheaper than making changes mid-production.

Rapid Prototyping:

After the CAD model is finalized, rapid prototyping brings the design to life. With 3D printing and CNC machining, the manufacturer creates a physical sample of the part quickly. This prototype is then tested to see how it holds up under conditions like the ones it will face in actual use. It's a real-world check that ensures the part will do its job precisely and efficiently. If it doesn't, you can go back, adjust the CAD model, and test once more.

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Step 3: Understand the Manufacturing Process

A clear understanding of the manufacturing capabilities and constraints is critical. Here's a concise overview:

CNC Machining:

This is a versatile process where material is precisely removed from a blank (or a block of plastic) to shape the component. It is ideal for creating complex parts that need to meet the tight tolerances required in aerospace. It can be done with 3-axis machines for simpler geometries or 5-axis machines for more complex designs. For even more complex designs, manufacturers can utilize even their 7-axis machines when a design has ultra-precise requirements and tolerances. Knowing the capabilities of your manufacturer’s machinery as well as the level of your part’s complexity are crucial for more elaborate designs.

Injection Molding:

Ideal for high-volume production, this method involves injecting molten plastic into a mold. It's cost-effective for large runs but requires significant upfront investment in mold design, making it less suitable for prototypes or small batches.

3D Printing:

For rapid prototyping or small batches, 3D printing is an excellent choice. It builds parts layer by layer, without the need for extensive tooling like in injection molding. It is used in aerospace for its ability to prototype complex geometries and produce lightweight, structurally optimized components. However, it may not match the production quality of CNC machined parts.

Bonding and Assembly:

Some parts are too complex to be made in one piece and require bonding of separate components to create a product. Material compatibility is vital here, as some plastics don't bond well together.

Finishing Processes:

Post-machining processes like polishing, painting, and surface treatments can improve the appearance, performance, and durability of the final product. These steps are often critical for parts that must withstand harsh aerospace environments, like those in extraterrestrial and space exploration.

By understanding these processes and discussing them with your manufacturer, you'll be able to design parts that are not just manufacturable but also meet the standards of the aerospace industry. Open communication about capabilities and constraints will help ensure quality results and a smooth partnership.

Step 4: Communicate Clearly and Collaborate Closely

A straightforward approach with detailed requirements and ongoing dialogue helps ensure that the aerospace parts you get are up to the mark, fitting perfectly into your project.

Specifications:

Be specific about what you need. Give detailed information on the part's size, shape, the plastic type (like PEEK or polyimides for high-temp resistance), tolerances, and surface finish. Remember to ask your manufacturer if your product needs features like bonding or polishing for optimal performance. This helps the manufacturer understand exactly what you're looking for and how the part should perform.

Active Communication:

Keep the conversation going. After seeing and testing the first prototypes, inform the manufacturer what works and what doesn't. This open and active communication helps fine-tune the design and ensures the final parts meet your standards and requirements. Continuous feedback leads to higher quality products while helping to avoid mistakes.

Step 5: Quality Assurance and Compliance

Ensure that all parts and components meet the aerospace industry’s strict standards.

Quality Assurance:

While your manufacturer should already have access to QA/QC staff in some capacity, it’s necessary to set up your own thorough testing and inspection processes. Make sure the parts go through stress tests, thermal tests, and material analyses to check they can handle the demands of aerospace environments.

Compliance:

Check that your manufacturer holds the right certifications, like AS9100. This ensures they follow the aerospace industry's quality management systems and produce parts that are reliable and up to the high standards set by these regulatory bodies.

Partner with the Best in Aerospace Plastics

As a trusted partner in aerospace plastic manufacturing, Controlled Fluidics stands out for our precision, expertise, and track record of success with industry giants like NASA. We excel in producing parts with extremely low tolerances and specialize in working with high-performance materials such as Vespel, ensuring your components endure the rigors of aerospace environments. For an aerospace partner who understands the complexities of your project and offers a seamless manufacturing process from design to delivery, choose Controlled Fluidics and request a tailored quote for your project today.