Demand for lightweight, high-performance materials, driven by the need for greater fuel and production efficiency, weight reduction, and sustainability, has propelled innovation in aerospace component manufacturing. Among these advancements, Xycomp® DLF™ (Discontinuous Long Fiber) composites have emerged as a uniquely qualified solution.
This white paper explores the advanced features of Xycomp® DLF™ and shares results from a validation test program developed in a collaborative effort between Greene Tweed and GE Unison. Suitability of DLF brackets for production service on commercial aircraft engines using compression-molded carbon/PEEK thermoplastic composite DLF materials is proven by this case study.
The case study also presents:
- The identification of functional requirements (including weight savings goals, design loads, and fastener torque/pullout expectations).
- Redesign of the baseline multi-piece legacy metallic component into a single-piece DLF solution.
- Analysis and prediction of performance capability.
- Manufacturing considerations.
- Compression molding of prototypes for mechanical testing.
- Xycomp® DLF™’s successful establishment of conformance to requirements.
This information has been curated to provide aerospace engineers and decision-makers with in-depth insights into Xycomp® DLF™’s capabilities and its role in advancing the future goals of aerospace materials engineering and operations teams.
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