Aerospace & Defense

Plastic Injection Molding for Aerospace & Military/Defense Industries

Aerospace Plastic Injection MolderAs a top plastic injection molding company for the aerospace and military/defense industries, we understand how important engineered plastics and composite materials are to modern component design.

Products must combine lightweight, high strength and temperature-resistant properties for structural components, electrical products and optical applications. Parts can be highly engineered to meet demanding requirements. Our careful quality control ensures adherence to part requirements, quality and consistency.

Typical tolerances are +/- 0.00025” (0.0064mm), confirmed using either measuring microscopes or fully automated (CMM) Coordinate Measuring Machines.

In general, plastic injection molding is not optimized for high-volume production, but rather carefully-controlled to reduce stress that would affect characteristics of the finished piece.

Materials & Processes

Most plastic injection molding for aerospace and military/defense applications involves engineered resins and complex mold cavities. Careful control of the molding process, including gate design, temperature and pressure is necessary to yield the highest quality parts.

Many parts require multiple post-molding services, including drilling, machining, plating and fabrication. PMC provides these services under one roof to maintain consistent management control – ‘One throat to choke.’ This helps reduced the cost of purchasing.

PMC is known as the ‘Go To’ molder who’s able to successfully complete a job after another molder tried and failed. Our certified in-house Master Molders, experience with complex projects, and our tight relationship with multiple resin suppliers gives us the expertise to get the project done right.

Special Considerations

Engineered resins and complex part design require going far beyond standard operations. It’s important to consider the physics of the molding process and the chemistry of what happens to resins at elevated temperatures.

Just as important, some resins are sensitive to temperature and pressure. Even if barrel temperatures are held to a minimum, sensitive compounds can undergo degradation if frictional gate dynamics are not monitored. There are many reasons why resins will NOT behave the same way from one shot to the next

Plastic Molded Concepts was an early champion of in-mold monitoring of shot pressure. By studying the behavior of viscous fluids (rheology), we can optimize the molding process for every cycle.

How to Get the Best Results

Defense contracts requiring a U.S. manufacturer with tight access controls, a disaster recovery plan and compliance with ITAR regulations often choose PMC as their chosen plastic molder since we meet all of these requirements.

Many aerospace and defense contractors partner with PMC early in the design/engineering process. They find this is the best way to get the product characteristics they need in a finished system. Sometimes this involves adjusting part design based on molding physics in order to minimize stresses and resin failures. We will suggest changes in draft angle and mold gate placement to distribute the resin evenly in the cavity.

We also address dimensional stability. The dimensional changes in the molded product (that can show up long after molding) are predictable and critical to understanding how to make parts with critical size requirements.

At the same time, program specifications are subject to change, and we are able to respond quickly to change orders. Even contractors that typically work with foreign suppliers find that they get better results by ‘Onshoring’ molding operations with PMC.

As a centrally-located U.S. plastic injection molding company, we can reduce time-to-market and turn a project into a revenue-generator quickly!

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