Award for aerospace application: Injection forming of CF-PAEK composite profiles with CF-PEEK by Herone (Sachsen, Germany) and partners TU Dresden and Victrex Europa.

The thermoplastic drive-shaft system overmolded with an integral gear, designed for use in aerospace, holds enormous potential, according to materials supplier Victrex.

The drive shaft is formed from “organoTubes,” braided preforms made from fully consolidated thermoplastic UD tapes; in this case, VICTREX AE 250 unidirectional tape, a carbon-fiber-PAEK composite. The process was developed by the Institute of Lightweight Engineering and Polymer Technology, TU Dresden, and Herone GmbH for use in the manufacture of continuous-carbon-fiber-PAEK composite hollow profiles. The organoTubes are then overmolded with Victrex PEEK 90HMF40, a carbon-fiber-PEEK composite, to incorporate the gear.