Making Weight with Die-Cut Flexible Components

In aerospace, every ounce counts. 

It’s not rocket science (well, technically it IS rocket science...) that eliminating excess weight boosts overall performance, payload capacity, and fuel savings in aerospace designs. But, as often is the case, manufacturers may not realize there was room for weight savings until it's too late, once material selection is already over. Working with a converter to select the proper material from the start is a crucial aspect of the design phase. 

In our last blog, Die-Cut Flexible Materials: Lighter, Scalable, Aerospace EMI/RFI Solutions, we highlighted five flexible die-cut EMI/RFI shielding materials that help aerospace manufacturers reduce weight without sacrificing shielding performance. Today, we’re building on that concept, highlighting some more lightweight, flexible aerospace solutions that solve a wide range of challenges beyond just EMI/RFI shielding. Die-cut flexible materials are great options for aiding in lightweighting initiatives while also solving many ancillary challenges like brightness mitigation, thermal management, insulation, and EMI/RFI shielding.  

Let’s take a look at some high-performance lightweighting materials... 

Lightweight Conductive Films

Pictured: 3M  Transparent Conductor Film 3M23-MS 

Applicable for: 

• Brightness mitigation

• Thermal control

• EMI/RFI shielding

Conductive films are a diverse option for solving multiple aerospace challenges, from brightness mitigation to EMI/RFI shielding. These films, like polyethylene terepthalates (PETs) and fluorinated ethylene propylenes (FEPs), provide the electrical shielding capabilities of metal in a thin, lightweight package. Available in thicknesses as low as 0.002 inches, conductive films provide around 60-80 dBs of shielding at half the weight of aluminum.  

The thin, flexible nature of conductive films opens a world of converting possibilities. Need a film to fit over complex geometries or tight spaces? Utilize tight tolerance die-cutting for precise parts. Need more rigidity? Laminate a PET film to a polycarbonate backing. Working with a converting partner like JBC Technologies is the key to custom materials for custom parts!

Elastomer Gaskets and Seals

Pictured: SSP502-60-V0 

Applicable for:

• EMI/RFI shielding

• Flame protection

• Sealing out contaminants

Thin, flexible elastomers, like SSP502-60-V0, provide great sealing, shielding, and flame protection in a lightweight, conformable package. When filled with conductive particles like aluminum, silver, or nickel-graphite, elastomer gaskets and seals prevent disruptive EMI/RFI from interfering with sensitive aerospace electronics like navigation and communication systems with a shielding effectiveness of 80-100dB at half the weight of metal alternatives. Custom die-cut elastomer gaskets also provide flame protection while sealing out contaminants like dust and dirt.  

Weighing significantly less than metal alternatives, elastomers can be die-cut to a variety of shapes including O-rings, gaskets, strips, and seals. Unlike metals, Elastomers are a truly custom solution, allowing you to tailor a material to fit your exact needs.  

Conductive Adhesives

Pictured: 3M Tape 9703 

Applicable for:

• EMI/RFI shielding

• Conductive structural bonding

• Low-gassing adhesion

Conductive adhesives are a multi-functional for lightweighting initiatives in aerospace manufacturing. Able to simultaneously provide a strong functional bond as well as lightweight EMI/RFI shielding, conductive tapes like 3M Tape 9703, are an efficient lightweighting material. With low-outgassing, 3M 9703 prevents contamination when bonding conductive films like FEPs and PETs in space environments.

Honeycomb Panels

Pictured: Hexcel HRH-310 Nomex Honeycomb 

Applicable for:

• Structural Integrity

• Thermal insulation

• Acoustic insulation

• Flame resistance

Honeycomb panels are an invaluable resource in aerospace manufacturing for reducing weight while ensuring rigid and durable structural integrity in areas like wings and fairings. Consisting of a honeycomb patterned core sandwiched between two thin facing skins, honeycomb panels offer an impressive strength to weight ratio as well as many other ancillary benefits like flame resistance. The honeycomb design reduces weight without sacrificing structural integrity. Compared to aluminum which typically has a core density of 2.7 g/cm, honeycomb panels range from about 0.03 to 0.5 g/cm.

Honeycomb panels, like the Hexcel HRH-310 pictured above, can also be utilized as thermal and acoustic insulators, keeping fire out and noise at bay. The air-filled cells in the honeycomb construction reduce heat transfer, keeping aerospace components cool at high temperatures.  

Insulation

Pictured: Formex™ GK 

Applicable for:

• EMI/RFI shielding

• Thermal insulation

• Electrical insulation

Formex™ GK is a high-performance insulation material that aligns well with lightweighting initiatives. Used anywhere sensitive aerospace electronics are packed together like battery packs or communications systems, Formex™ GK prevents critical failures like short circuits and fires by preventing electronic components from touching.

Formex™ GK has high dielectric strength, flame retardancy, as well as moisture and chemical resistance, all in a lightweight package. Able to be die-cut, scored, and folded, GK material is a highly customizable option for fitting tight aerospace electronics compartments. With a low density of 1.035 g/cc and available in a wide range of thicknesses, Formex™ GK is a great option for high-performance insulation, without the extra pounds.

Check out this Formex™ GK Material Spotlight for a more in-depth look!