Aircraft Interiors Expo (AIX), Hamburg, Germany, Hall B6, Stand 6E80, June 6, 2023 – Tool Gauge, a U.S. manufacturer of complex, high-value plastic and metal assemblies for global aerospace original equipment manufacturers (OEMs), and Victrex, a global leader in PEEK- and PAEK-based polymer solutions, today announced that they will collaborate to develop a new co-molding technology for the aerospace industry. This new technology will use formed carbon composites combined with carbon filled thermoplastics.  

“The aerospace industry continues to increasingly adopt thermoplastic materials as they lower aircraft weight, reduce time and waste from machined metals, and provide sustainable goods for our future,” explains Jim Lee, general manager of Tool Gauge. “As part of this collaborative project with Victrex, we aim at replacing machined aluminum components used in commercial aircrafts that are currently expensive and take months to produce with new thermoplastic composite versions.” 

 The fabrication of the proposed thermoplastic utilizes hybrid overmolding where thin sheets of carbon fibers are combined with Victrex’s LMPAEK™ polymer, creating a unidirectional tape. This material is then stacked and consolidated into one panel with the application of heat and pressure, with small pieces cut from the panel. Finally, the short-fiber reinforced PEEK compound is injection molded onto the insert. A fusion bond similar to a weld forms between the PEEK compound and LMPAEK™ composite insert as the molten PEEK melts the surface of the insert. As the part cools, the PEEK compound and LMPAEK™ composite solidify as one piece. 

The hybrid overmolding process creates a part that is mechanically stronger and stiffer than a part only made with PEEK compound due to the continuous fiber reinforcement used in the composite insert. The hybrid overmolding combines injection molding with thermoforming to create a finished part that is lighter, cheaper, produces less waste, can be produced faster, and has superior fatigue performance.  

“As a solution provider, Victrex firmly believes that the path to innovation lies in understanding customer needs and pioneering solutions where PEEK and PAEK deliver a strong advantage,” adds Jonathan Sourkes, head of market and business development for Victrex. “Through this, we continue to redefine what is possible, delivering transformative solutions that address pressing, unmet industry needs. Our commitment to innovation and strategic collaborations enables us to be at the forefront of technological advancements, driving progress and creating a more sustainable future for industries worldwide.” 

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 About Tool Gauge 

Founded in 1966 and headquartered in Tacoma, Washington, USA, Tool Gauge manufactures complex, high-value plastic and metal parts and assemblies. Global aerospace OEMs and tier-one aircraft interior integrators trust Tool Gauge for its high product quality, on-time delivery, and continuous adoption of new technology. The company has been the proud recipient of Boeing’s Silver / Silver Performance Award for manufacturing excellence for the past 10 consecutive years (2012-2022). For more information, please visit our web site or follow us on LinkedIn and Twitter (https://twitter.com/toolgauge).  

About Victrex  

Victrex is an innovative world leader in high-performance PEEK (Poly Ether Ether Ketone) and PAEK (Poly Aryl Ether Ketone) polymer solutions focusing on the strategic markets of automotive, aerospace, energy, industrial, electronics, and medical. Every day, millions of people use products and applications containing our materials – from smartphones, aircrafts, and cars to energy operations and medical devices. With over 40 years of experience, we are developing world-leading solutions with PEEK- and PAEK-based polymers and selected semi-finished and finished parts which enable environmental and societal benefit for our customers and our markets as well as drive value for our shareholders. Please visit our web site for more information.

©2023 Victrex plc. VICTREX™ and LMPAEK™ are trademarks of Victrex plc or its group companies. All rights reserved. 

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