How Modular Tooling Accelerates Thermoplastic Composite Prototyping for Advanced Air Mobility and Defense

A new prototyping approach leverages thermoplastic composites, swappable cavity inserts and modular tooling to reduce the time required to produce aerospace and defense prototypes by up to 50 percent. Developed by Greene Tweed - the Pennsylvania-based manufacturing and design services provider - the approach is seeing increased demand among advanced air mobility (AAM) and defense companies focused on metal-replacement development projects that require faster testing and validation.

Greene Tweed developed its new rapid prototyping process using its Xycomp^® DLF™ material, which the company first introduced to commercial aerospace in 2007. Xycomp DLF is a thermoplastic composite that provides a lightweight alternative to complex metallic components for aerospace and defense applications. According to Greene Tweed, Xycomp DLF components can weigh up to 60 percent less than their metal counterparts and are well suited for aircraft, engine and aerostructure applications.