This white paper explores the advanced features of Xycomp® DLF™, a high-performance thermoplastic composite material made of chopped discontinuous long fiber (DLF) flakes, detailing its material properties,
Zero-waste automated manufacturing techniques, rigorous testing processes, and real-world applications.
It also shares results and conclusions from a validation test program developed in a collaborative effort
between Greene Tweed and GE Unison. In this case study, the team proved the suitability of DLF brackets for production service on commercial aircraft engines using compression-molded carbon/PEEK thermoplastic composite DLF materials.
The case study also presents:
• The identification of functional requirements (including weight savings goals, design loads,
and fastener torque/pullout expectations).
• Redesign of the baseline multi-piece legacy metallic component into a single-piece DLF solution.
• Analysis and prediction of performance capability.
• Manufacturing considerations.
• Compression molding of prototypes for mechanical testing.
• Xycomp® DLF™’s successful establishment of conformance to requirements