Soaring to New Heights: Precision Injection Molding for Israeli Aerospace Imaging Systems with SABIC DU242

This case study details the successful collaboration between our mold manufacturing facility and an Israeli aerospace technology company to develop critical plastic components for aircraft camera systems. Using SABIC's DU242 material, we overcame significant engineering challenges to deliver components that meet stringent aerospace requirements for precision, durability, and environmental resistance.

In the precision-driven aerospace industry, the margin for error is virtually nonexistent. When a leading Israeli developer of advanced aerial imaging systems approached us with a challenging project, we recognized it as an opportunity to demonstrate our expertise in high-performance injection molding. Their requirement: to produce complex, high-tolerance plastic components for their next-generation aircraft camera systems using SABIC's DU242 material.

Our client is an innovative Israeli aerospace technology firm specializing in sophisticated photographic and surveillance systems for military and commercial aircraft. Their systems operate in extreme environmental conditions, requiring components that maintain structural integrity and dimensional stability across temperature variations from -40°C to 85°C.

The project involved manufacturing three critical components:

1.A main housing unit requiring exceptional dimensional stability

2. Internal lens mounting components with precise tolerances (±0.015mm)

3.External protective covers with high impact resistance

• Maintaining strict tolerances under varying thermal conditions

• Achieving required mechanical strength while minimizing weight

• Ensuring resistance to aviation fuels, chemicals, and UV radiation

• Meeting stringent aerospace certification standards

After comprehensive evaluation, we selected SABIC's DU242, a glass-filled polypropylene compound, for its exceptional properties:

• Excellent stiffness and dimensional stability

• Low coefficient of thermal expansion

• Superior chemical and moisture resistance

• Good flow characteristics for complex geometries

• UV stability for external applications

• Designed multi-cavity molds with conformal cooling channels

• Implemented vacuum venting systems to prevent air traps

• Used premium mold steel with specialized surface treatments

• Incorporated sensor technology for real-time process monitoring

• Strict material handling and drying procedures (4 hours at 80°C)

• Optimized injection parameters through DOE methodology

• Maintained melt temperature within ±2°C tolerance

• Implemented automated vision inspection systems

• First article inspection with CMM verification

• Statistical process control throughout production

• Environmental stress testing on random samples

• Full documentation and traceability per aerospace standards

• Achieved consistent dimensional accuracy within ±0.012mm

• Maintained CTI rating of 600V for electrical components

• Achieved UL94 V-0 flammability rating

• Demonstrated impact resistance exceeding requirements by 35%

• Achieved 99.2% production yield rate

• Reduced cycle time by 18% through process optimization

• Maintained CpK values above 1.67 for critical dimensions

• Implemented zero-defect delivery program

• 30% weight reduction compared to previous designs

• 40% improvement in environmental resistance

• 25% cost reduction through design optimization

• Accelerated time-to-market by 6 weeks

This project exemplifies our capability to deliver aerospace-grade injection molding solutions that meet the most demanding requirements. The successful implementation of SABIC DU242 material, combined with our precision engineering and manufacturing expertise, enabled our Israeli client to enhance their product performance while reducing overall costs.

The collaboration has led to an ongoing partnership, with our facility now serving as the client's preferred manufacturing partner for all their injection molding requirements. This success story demonstrates how strategic material selection, coupled with advanced manufacturing capabilities, can create significant competitive advantages in the aerospace industry.

We continue to innovate with advanced materials like SABIC DU242, pushing the boundaries of what's possible in precision injection molding. Our commitment to excellence ensures that we remain at the forefront of manufacturing technology, ready to meet the evolving challenges of the aerospace sector and beyond.