#08 – High-Performance Plastics for Defence & Critical Applications
Two materials for one critical assembly
Defence and security systems combine demanding requirements: vibration, temperature extremes, sensitive electronics and long service intervals. Components for these systems are typically needed in small quantities, with documented material identification and short lead times. PEI ULTEM™ and PAI Torlon® address two different requirements within critical assemblies: electrical insulation and mechanically loaded wear performance.
The challenge
Sensor systems, electro-optical equipment and mobile platforms often need two very different component types within the same assembly: electrically insulating precision parts and mechanically highly loaded wear parts. Injection moulding is rarely economical at these quantities. Metallic components can influence electromagnetic signal propagation and may require additional insulation or RF-specific design measures. In addition, procurement for critical programmes increasingly asks for reliable manufacturing sources with documented material certificates.
The solution
COMCO EPP covers both component types from one source, CNC-machined from stock shapes.
PEI ULTEM™ is our choice for insulators, connector bodies and sensor carriers. The amorphous high-performance thermoplastic offers very good dielectric properties, inherent flame resistance and a continuous operating temperature of about 170 °C. Machined from Comco-PEI sheet or rod, PEI ULTEM™ components are used where electrical insulation, low weight and dimensional stability are required.
PAI Torlon® takes over where mechanical load and wear exceed the limits of many other thermoplastics. PAI Torlon® offers outstanding strength among melt-processable thermoplastics and remains usable under demanding conditions up to about 260 °C, depending on grade and load profile. Machined from rod, PAI Torlon® is used for bushings, bearing elements and structural parts in actuators and guide systems. Tribologically modified PAI Torlon® grades are designed for low-lubrication operation; the suitability for a
specific bearing application is verified against the actual load profile.
Both materials are CNC-machined in our own production. No tooling costs, no moulding-typical minimum volumes, batch documentation on request.
ULTEM™ is a trademark of SABIC. Torlon® is a registered trademark of Syensqo.
“In critical applications the material decision is a risk decision. Our task is to support it with material knowledge and documented quality.”
Typical machined components for defence and critical applications
- Electrical insulators and connector bodies
- Sensor carriers and electro-optical mounting components
- Bushings and bearing elements for actuators
- Guide elements and precision wear parts
- Structural supports and spacers
- Housing and cover components
- CNC-machined prototypes and small-series components
Material properties at a glance
PEI ULTEM™ (electrical and thermal):
- Very good dielectric properties and electrical insulation
- Inherent flame resistance, low smoke emission
- Continuous operating temperature of about 170 °C
- Semi-transparent, dimensionally stable, machinable to tight tolerances
PAI Torlon® (mechanical and tribological):
- Outstanding strength and stiffness among melt-processable thermoplastics
- Usable under demanding conditions up to about 260 °C, depending on grade
- Tribological grades for low-lubrication wear applications
- Machined from rod, from single parts to small series
What critical programmes require
Critical programmes require more than suitable material properties. Reproducible machining quality, controlled material identification, material certificates on request, revision-controlled production and discreet handling of customer drawings are equally important. CNC machining from stock shapes also allows prototypes, replacement parts and small series to be produced without moulding tools.
Why COMCO EPP
COMCO EPP combines material selection, stockholding and in-house CNC machining. For critical applications this means short lead times, material certificates on request, discreet handling of customer drawings and one
technical partner from material selection to finished component.
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