Aerospace & Defense Technology - December 2023 - 18

Materials
One prevalent misconception is that
polymers lack the strength and durability
required for demanding applications.
However, advancements in highstrength
3D-printed polymers have
effectively closed the performance gap
between plastics and certain metals.
These materials now offer mechanical
properties that meet or exceed stringent
performance requirements.
Another misperception revolves
around the suitability of plastics in
high-temperature environments. While
it's true that some plastics have limitations
in extreme temperatures, there are
high-temperature polymers available
that can withstand challenging thermal
conditions, making them viable alternatives
to metals and low-temperature
materials that can withstand extreme
cold temperatures.
The aerospace and defense industries
Essentium develops a wide range of 3D-printed materials.
have access to high-impact, high-temperature
thermoplastic materials. These
high-performance materials empower
manufacturers to rapidly produce end
parts that meet industry reliability,
repeatability, and performance standards.
Our new materials offer impact
resistance five times that of PEI 9085
while remaining cost competitive. The
material can withstand temperatures of
up to 150 °C, is resistant to flame, smoke,
and toxicity (FST), and has passed FAR
25.853 FST testing.
Another false belief is that plastics
Essentium's 3D-printing machines have been used to manufacture drones and other aerospace and
defense technologies.
durability, even after accidental drops
or impacts. Utilizing these materials can
significantly reduce the weight of tools
and production aids compared to their
metal counterparts.
In addition to these strengths, highstrength
3D-printed plastics offer design
freedom, enabling the production of
complex geometries that are often challenging
to achieve with metal parts.
This allows for part consolidation, optimization,
enhanced performance, and
18
reduced assembly time. The speed of 3D
printing facilitates faster prototyping,
production cycles, iterations, and shorter
time to market.
Addressing Misconceptions About
3D-Printed Plastics
Despite the capabilities of highstrength
3D-printed plastics, there are
common misconceptions about their
feasibility as alternatives to metals in
aerospace and defense applications.
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cannot achieve the desired aesthetic
finishes. The latest generation of plastics
is highly amenable to post-processing
techniques and can be painted
or treated to achieve the desired visual
appearance.
Lastly, there's a perception that plastic
parts are less reliable or prone to failure.
However, with proper design and manufacturing,
high-strength 3D-printed
plastics can provide exceptional reliability
and durability, meeting stringent performance
requirements.
Navigating the Transition
Transitioning from traditional metals
to high-strength 3D-printed plastics
presents specific challenges and tradeoffs
that organizations must consider. Selecting
the most suitable material for a particular
application is a critical challenge.
Aerospace & Defense Technology, December 2023

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Aerospace & Defense Technology - December 2023

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