SAMPE Journal - March/April 2020 - 16

FEATURE

THERMOPLASTIC COMPOSITE
BRACKET
Developing A Hybrid PAEK Overmolded
Thermoplastic Composite Bracket
Frank J. Ferfecki

Tyler Smithson

Chris Bjerregaard

Victrex USA Inc.

Safran Cabin

Tri-Mack Plastics Manufacturing Corp.

West Conshohocken, PA

Huntington Beach, CA

Bristol, RI

ABSTRACT

T

here is a growing interest in the use of thermoplastic composite materials within the aerospace
industry because parts can be manufactured faster at lower cost and weight. Developments in high
performance thermoplastics are enabling emerging technologies, such as composite overmolding, to

widen even further the opportunities for high production throughput and design flexibility, while retaining
excellent mechanical properties by combining continuous fiber structures with short fiber reinforced
overmolded features. In particular, one variant of a Polyaryletherketone (PAEK) is enabling direct overmolding
of Polyetheretherketone (PEEK) for this purpose. One area of development in the aerospace industry includes
the substitution of selected metallic brackets with thermoplastic composite brackets. The paper outlines the
development of a load bearing thermoplastic hybrid bracket to replace a metal aircraft crash bracket. The
bracket consists of continuous carbon fiber PAEK laminate inserts which are injection overmolded with a short
carbon fiber filled PEEK resin compound. The paper outlines initial design, part manufacture, testing, trouble
shooting and redesign. The paper presents simulations of the process and structure, molding parameter
development, insert design, describes unexpected issues and resolutions. The composite bracket resulting
from this work provides a significant weight saving over the aluminum bracket it replaces.

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SAMPE Journal - March/April 2020

Table of Contents for the Digital Edition of SAMPE Journal - March/April 2020

Table of Contents
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SAMPE Journal - March/April 2020 - Table of Contents
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SAMPE Journal - March/April 2020 - Cover3
SAMPE Journal - March/April 2020 - Cover4
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