SAMPE Journal - September/October 2016 - 29

Feature Article

Figure 2. Xycomp® DLF thermoplastic material and compression molded parts.

DLF Composites
Greene, Tweed's Xycomp® DLF is produced by
slitting and chopping carbon fiber reinforced pre-preg
unidirectional tape into "flakes" or "chips" with specified
dimensions (Figure 2). The chopped random-oriented
DLF flakes are subsequently compression molded in
matched-die metal tooling to create final parts. Net or
near-net shape composite components with complex
geometry and molded-in features can be compression
molded using these materials, as shown in Figure
2. Matrix polymers for DLF materials in aerospace
applications may be thermoplastic (typically PEEK
or PEKK) or thermoset (typically epoxy) of which the
work presented focuses on the use of PEEK and PEKK
thermoplastic matrix materials for its DLF offering.
DLF materials have the ability to form features such
as molded-in holes, ribs, bosses, gussets, flanges,
thickness changes, corners, and identification labeling
with minimal added process difficulty. This provides
much greater design freedom than continuous fiber
materials. Secondary metallic components such as
threaded inserts (blind or through), nut-plates, and
bushings can also be incorporated during the molding
process. Examples of typical complex design features
are shown in Figure 3.
One example of a complex-shape DLF application is
an aerodynamic fairing rib for the landing gear skid of
an eco-friendly helicopter. Activities in a demonstrator
project, part of the Clean Sky Programme, undertaken
by Greene, Tweed & Co. for its customer, focused on

demonstrating suitability of DLF ribs for production
service using compression molded carbon/PEEK DLF
thermoplastic composite materials.
Clean Sky Programme
Founded in 2008, Clean Sky is a public-private
partnership between the European Commission and the
European aeronautics industry4. Clean Sky is a major
contributor to reaching the 2020 goals set by the Advisory
Council for Aeronautics Research in Europe (ACARE).
These goals are: 50% reduction in fuel consumption
and carbon dioxide emissions, 80% reduction in nitrous
oxides emissions, external noise reduction of 50%,
and improved environmental impact of the lifecycle of
aircraft and related products (all compared with levels in
the year 2000).

Unique Polyamide
*
*
*
*

High Modulus and Stre
Strength
r ngth
re
Easy Molding
Water Resistance
Good Surface Appearance

MITSUBISHI GAS CHEMICAL AMERICA
www.mgc-a.com
composite@mgc-a.com

Figure 3. Examples of typical DLF molded-in features.
SAMPE Journal, Volume 52, No. 5, September/October 2016

29



http://www.mgc-a.com

Table of Contents for the Digital Edition of SAMPE Journal - September/October 2016

Contents
SAMPE Journal - September/October 2016 - Cover1
SAMPE Journal - September/October 2016 - Cover2
SAMPE Journal - September/October 2016 - Contents
SAMPE Journal - September/October 2016 - 2
SAMPE Journal - September/October 2016 - 3
SAMPE Journal - September/October 2016 - 4
SAMPE Journal - September/October 2016 - 5
SAMPE Journal - September/October 2016 - 6
SAMPE Journal - September/October 2016 - 7
SAMPE Journal - September/October 2016 - 8
SAMPE Journal - September/October 2016 - 9
SAMPE Journal - September/October 2016 - 10
SAMPE Journal - September/October 2016 - 11
SAMPE Journal - September/October 2016 - 12
SAMPE Journal - September/October 2016 - 13
SAMPE Journal - September/October 2016 - 14
SAMPE Journal - September/October 2016 - 15
SAMPE Journal - September/October 2016 - 16
SAMPE Journal - September/October 2016 - 17
SAMPE Journal - September/October 2016 - 18
SAMPE Journal - September/October 2016 - 19
SAMPE Journal - September/October 2016 - 20
SAMPE Journal - September/October 2016 - 21
SAMPE Journal - September/October 2016 - 22
SAMPE Journal - September/October 2016 - 23
SAMPE Journal - September/October 2016 - 24
SAMPE Journal - September/October 2016 - 25
SAMPE Journal - September/October 2016 - 26
SAMPE Journal - September/October 2016 - 27
SAMPE Journal - September/October 2016 - 28
SAMPE Journal - September/October 2016 - 29
SAMPE Journal - September/October 2016 - 30
SAMPE Journal - September/October 2016 - 31
SAMPE Journal - September/October 2016 - 32
SAMPE Journal - September/October 2016 - 33
SAMPE Journal - September/October 2016 - 34
SAMPE Journal - September/October 2016 - 35
SAMPE Journal - September/October 2016 - 36
SAMPE Journal - September/October 2016 - 37
SAMPE Journal - September/October 2016 - 38
SAMPE Journal - September/October 2016 - 39
SAMPE Journal - September/October 2016 - 40
SAMPE Journal - September/October 2016 - 41
SAMPE Journal - September/October 2016 - 42
SAMPE Journal - September/October 2016 - 43
SAMPE Journal - September/October 2016 - 44
SAMPE Journal - September/October 2016 - 45
SAMPE Journal - September/October 2016 - 46
SAMPE Journal - September/October 2016 - 47
SAMPE Journal - September/October 2016 - 48
SAMPE Journal - September/October 2016 - 49
SAMPE Journal - September/October 2016 - 50
SAMPE Journal - September/October 2016 - 51
SAMPE Journal - September/October 2016 - 52
SAMPE Journal - September/October 2016 - 53
SAMPE Journal - September/October 2016 - 54
SAMPE Journal - September/October 2016 - 55
SAMPE Journal - September/October 2016 - 56
SAMPE Journal - September/October 2016 - 57
SAMPE Journal - September/October 2016 - 58
SAMPE Journal - September/October 2016 - 59
SAMPE Journal - September/October 2016 - 60
SAMPE Journal - September/October 2016 - 61
SAMPE Journal - September/October 2016 - 62
SAMPE Journal - September/October 2016 - 63
SAMPE Journal - September/October 2016 - 64
SAMPE Journal - September/October 2016 - 65
SAMPE Journal - September/October 2016 - 66
SAMPE Journal - September/October 2016 - 67
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SAMPE Journal - September/October 2016 - 69
SAMPE Journal - September/October 2016 - 70
SAMPE Journal - September/October 2016 - 71
SAMPE Journal - September/October 2016 - 72
SAMPE Journal - September/October 2016 - 73
SAMPE Journal - September/October 2016 - 74
SAMPE Journal - September/October 2016 - 75
SAMPE Journal - September/October 2016 - 76
SAMPE Journal - September/October 2016 - 77
SAMPE Journal - September/October 2016 - 78
SAMPE Journal - September/October 2016 - 79
SAMPE Journal - September/October 2016 - 80
SAMPE Journal - September/October 2016 - 81
SAMPE Journal - September/October 2016 - 82
SAMPE Journal - September/October 2016 - 83
SAMPE Journal - September/October 2016 - 84
SAMPE Journal - September/October 2016 - 85
SAMPE Journal - September/October 2016 - 86
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SAMPE Journal - September/October 2016 - 88
SAMPE Journal - September/October 2016 - 89
SAMPE Journal - September/October 2016 - 90
SAMPE Journal - September/October 2016 - 91
SAMPE Journal - September/October 2016 - 92
SAMPE Journal - September/October 2016 - 93
SAMPE Journal - September/October 2016 - 94
SAMPE Journal - September/October 2016 - 95
SAMPE Journal - September/October 2016 - 96
SAMPE Journal - September/October 2016 - 97
SAMPE Journal - September/October 2016 - 98
SAMPE Journal - September/October 2016 - 99
SAMPE Journal - September/October 2016 - 100
SAMPE Journal - September/October 2016 - 101
SAMPE Journal - September/October 2016 - 102
SAMPE Journal - September/October 2016 - 103
SAMPE Journal - September/October 2016 - 104
SAMPE Journal - September/October 2016 - 105
SAMPE Journal - September/October 2016 - 106
SAMPE Journal - September/October 2016 - 107
SAMPE Journal - September/October 2016 - 108
SAMPE Journal - September/October 2016 - 109
SAMPE Journal - September/October 2016 - 110
SAMPE Journal - September/October 2016 - 111
SAMPE Journal - September/October 2016 - 112
SAMPE Journal - September/October 2016 - 113
SAMPE Journal - September/October 2016 - 114
SAMPE Journal - September/October 2016 - 115
SAMPE Journal - September/October 2016 - 116
SAMPE Journal - September/October 2016 - 117
SAMPE Journal - September/October 2016 - 118
SAMPE Journal - September/October 2016 - 119
SAMPE Journal - September/October 2016 - 120
SAMPE Journal - September/October 2016 - Cover3
SAMPE Journal - September/October 2016 - Cover4
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