Xycomp® DLF

Xycomp® DLF™ is a lightweight thermoplastic composite developed to replace complex-shape metallic components for aerospace applications, and provides value in other demanding environments like defense, space, Industrial Operations and more. With outstanding fatigue, vibration, and impact resistance, it typically provides a 35-50% weight savings to help reduce emissions and fuel burn while providing exceptional performance. Xycomp® DLF™ is produced from aerospace-grade, carbon fiber-reinforced, unidirectional prepreg tape which is chopped into flakes, resulting in high fiber content (70% by weight), longer fibers (0.5 in./13 mm or greater), and a high degree of material control. Flakes are matched-die compression molded in a proprietary process called ProFusion®, enabling the production of 3D shapes with variable wall thickness and molded-in features such as fasteners, inserts, and ribs. The benefits of this molding technique include the consolidation of complex assemblies into fewer parts, and the optimization of raw material required per component (buy-to-fly ratio).

In addition to these properties, Xycomp® DLF™ is resistant to all common aerospace fluids. Xycomp® DLF™ components pass both FST (flame, smoke, toxicity) standards and the 15-minute burn-through requirement, making them ideal for use in aircraft interiors, engines, nacelles, or aerostructures. Through investment in extensive technical capabilities, Greene Tweed partners with customers from concept and design analysis, through certification, to production. Xycomp® DLF™ components are manufactured with nearly zero waste, and are fully recyclable at the end of their service life.