Aerospace fuel housing made from Victrex PEEK polymer

Fusible-core technology enables design of complex PEEK fuel housings

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  • Combination of fusible-core technology and PEEK
  • 30% cost savings, up to 50% weight reduction
  • Superior fatigue performance compared to aluminum

Fuel housings for aerospace applications have very complex inner geometries which are not moldable using conventional injection molding technology. Egmond Plastic‘s fusible-core technology in combination with PEEK polymer of Victrex enables moldings of such complex hollow housings, manifolds, and pipes. Cost savings of more than 30% and weight savings of up to 50% compared to existing metal designs can be achieved. Carbon fiber reinforced PEEK grades eliminate the use of a separate bearing, for example, since this is now integrated into the overall design of the housing.

Combination of fusible-core technology and PEEK

The technology, in combination with carbon fiber reinforced PEEK polymer, provides several advantages including cost reduction, higher manufacturing speed, and weight reduction. Along with part consolidation, this technology and material combination enables the design of very complex parts, beyond the capabilities of standard injection molding and metal processes.

Aerospace fuel housing made from Victrex PEEK polymer

Aerospace fuel housing made from Victrex PEEK polymer achieves a 50% weight savings (source: Victrex)

30% cost savings, up to 50% weight reduction

Utilizing a near net-shape manufacturing process for the fusible core allows for an 80% time saving versus machined parts. Secondary treatments for corrosion protection, such as anodizing, can be eliminated. Lead times can be reduced by 50%. These factors collectively result in part cost savings of more than 30% versus metal equivalents.

Superior fatigue performance compared to aluminum

Previously, the end-user had generally specified aluminum for the production of fuel containing parts, but a carbon fiber reinforced PEEK polymer demonstrated superior fatigue performance when compared to aluminum. It does this while meeting all the engineering requirements for this application, including stiffness, effective flame, smoke and toxicity (FST) performance, and resistance to aggressive chemicals, including notably, for this aerospace application, resistance to jet fuel and Skydrol* hydraulic fluid. Parts can range in size all the way up to 30 cm x 30 cm x 40 cm (11.8 in x 11.8 in x 15.8 in), and typically the process is used for production runs of up to 2,000 parts.

Egmond’s fusible-core technology in combination with PEEK has already been used in a fuel pump for the Eurofighter Typhoon, a jet fighter in use in several European countries. This pump has been in successful operational use for more than 20 years.



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