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The Aerospace & Aviation Industry

Aerospace and Avaiation Industry

Throughout the aerospace sector, technological advances make it imperative for designers, developers and engineers to stay abreast of constant innovations. At American Micro Industries, we've helped our clients implement solutions for custom aerospace industry components since the mid 1990s. Today, the industry is thriving better than ever thanks to the following materials.

Sheet Absorbers

Flat sheet absorbers offer protection against wandering currents and make it easy to control the patterns of antennas in the aerospace industry. With their range of advantages, sheet absorbers can be of great benefit when applied to custom die cut parts for aerospace industry components. Various sheet absorbers exist on today's market, including the following:

Types of Sheet Absorbers

  • Broadband carbon/foam flexible radar absorbers. These components are made from lossy open-cell plastic foam, and the material can be applied to surfaces with mild curvature. The material can also be found in versions that withstand harsh, wet weather conditions. They typically feature a colored surface with tarp coating.
  • Reticulated foam absorber sheets. Made out of urethane foam, this material is covered with gradient lossy coating having or involving the dissipation of electrical or electromagnetic energy. Reticulated absorber sheets can be used to divide antennas within close proximity, and they shield nearby equipment sets from one another. Thanks to its open-cell structure, that material allows easy airflow, and it also allows rain to drain freely.
  • Lossy carbon-loaded flexible foam microwave absorber sheets. Made of lightweight plastic foam, microwave absorber sheets are capable of absorbing stray radiofrequency energy. The material is easy to cut, and it can be found in various levels of thickness.
  • Tuned frequency magnetic microwave absorbers. Magnetic absorbers of this variety are capable of withstanding various types of weather as well as a wide range of temperatures. The material can be attached to metal, and it is generally applicable to aircraft parts. Magnetic absorbers also work well on the surfaces of nose cones, ship masts and similar items.

Whether they come in microwave or adhesive varieties, sheet absorbers are an important material in the aerospace and aviation sector. At American Micro Industries, we help clients implement use of such materials as needed, along with CNC machining for aerospace industry components and equipment.

Dielectric Materials

Dielectric materials are an important part of custom die cut components for aerospace industry arsenals. The purpose of dielectric material isn't to conduct electricity, but to polarize it. Such material helps to block interference by channeling signals and preventing them from straying. Therefore, dielectric materials like the following examples are often used for capacitors and transmission lines:

  • Plastic stock with adjusted dielectric constant. Plastic stock is used on a range of applications that necessitate adjusted dielectric constant. The material offers low-loss tangent, and its generally good for various components that are used daily in the aerospace industry. Certain variations of the material consist of high temperature-threshold plastic for more intense settings.
  • Low dielectric constant, low-loss sheet stock. This material consists of a rigid syntactic foam that boasts a fine texture. With its strong physical properties, it's easily applicable for CNC machining for aerospace industry components. The material is often used for antennas and coaxial support. Coils equipped with this material generally perform better.
  • Low-loss polystyrene sheet and rod stock. This material is made of cross-linked polystyrene a thermosetting plastic. As such, the material doesn't melt in hot conditions. Polystyrene sheet is most often used for antenna insulators and microwave lenses, as well as for various parts along transmission lines and waveguides.
  • Lightweight artificial dielectric material. Consisting of epoxy plastic resins, in addition to glass microspheres, artificial dielectric materials are used for various aerospace industry components. Examples of items on which the material is often applied include antenna parts, bars, cast plate and assorted aircraft parts.
  • Low Dielectric Constant
  • Low dielectric constant, low-loss structural foam. This material is valued for its high compression quality, as well as for its pure strength. Structural foam of this nature has a low-loss factor, and it works as a thermal barrier and radiofrequency window material, which makes the material a vital part of precision manufacturing for aerospace industry components.
  • Flexible, low-loss foam. Consisting of closed-cell flexible foam sheets, this type of material is suited for applications that need dielectric substrates. Low-loss foam is commonly used for radiofrequency transparent radomes because of the material's weatherproof quality. In addition to its lack of water absorption, the crack-proof material is good at withstanding sunlight.
  • Flexible, weatherproof low-signature plastic fabric. This material is made of nylon fabric and is covered with an elastomeric binder that resembles polychloroprene. As such, the material is sharp to the eye and easy to maintain. Thin, workable and water-resistant, the material can stand up to UV rays, and it also has solid mechanical properties.
  • Rigid foam liquid polyurethane. This material originates from liquid resins, which expand into a solid polyurethane plastic foam that boasts solid electrical properties. The material is chiefly used for cavity filling in microwave components and other electronics, including waveguides. However, the material is moisture-sensitive, so it must be stored in sealed nitrogen purged containers.
  • Lightweight syntactic foams. Syntactic foams of the lightweight variety are made for curing operations. The main purpose for such material is to stop resin from flowing into blocks that have already been cured. Additionally, the material is suited for parts that need to be encapsulated, because the thermal-shrinkage factor is minimal.
  • Cyanate ester syntactic foams. Material of this variety is highly convenient for custom components in the aerospace industry, because it's made in several variations, including uncured and cured sheet stock, which are molded into shape. With metallic fillers, the dielectric parameters of this material can even be adjusted for a broader range of options.

At American Micro Industries, we strive to stay abreast of the material needs of the aerospace sector. In doing so, we constantly look for new ways to innovate in the implementation of custom components for aerospace industry products. Thankfully, the variety of dielectric materials that are currently available has provided the industry with numerous options on how to make components better.

Honeycomb

When it comes to precision manufacturing for aerospace industry components, honeycomb is an essential material in flat sheet and pyramidal form. Three different types of the flat-sheet kind exist HCGR (Graded Reflectivity), HCGI (Graded Insertion Loss) and HCUI (Uniform Insertion Loss). The material is commonly used for the purpose of bulk absorption and antenna isolation:

Honey Comb Absorbers
  • Broadband honeycomb absorbers. Consisting of phenolic material of either the Nomex or glass variety, honeycomb features a hexagonal, open-cell structure that makes it solid at a minimum of weight. As such, the lossy-coated material is suited for covers, fairings and other aircraft parts.
  • Honeycomb pyramidal absorber. High-power absorbers that consist of pyramidal plastic honeycomb are specially treated for some of the more crucial custom aerospace industry components. With its unique design, the material allows for functions that wouldn't be possible with other types of material used in aircraft.

Custom components for aerospace industry designs will often call for honeycomb material. Depending on the specs of a given design, flat or pyramidal versions of the material might be in order. In any case, the open-cell structure allows for functions that simply can't be achieved with other types of material.

Radiofrequency Suppression

Radiofrequency suppression materials are made to reduce electromagnetic waves that resonate inside cavities. In the form of sheets, these materials can be custom die-cut according to the specs of designs. Radiofrequency suppression materials are made with adhesive backing of a pressure-sensitive strength. Alternately, stronger adhesive backings can also be chosen for settings where conditions are more severe. Examples include the following materials, which are often applied to custom components for aerospace industry arsenals:

Radio Suppression Materials
  • Tuned frequency magnetic sheet absorbers. In the world of aerospace, sheet absorbers of the tuned-frequency magnetic variety can be invaluable for a number of functions. Due to their thin quality and flexible nature, the material is typically used for nose cones and ship masts, and also to attach various components to aircraft structures.
  • High-loss magnetic sheet absorbers for surface waves. Absorbers of this kind are made of soft material, which is either die-cut or razor-cut. Consisting of silicone, high-loss magnetic sheet absorbers have the power to withstand a range of temperatures as well as to endure harsh weather conditions. Thin and applicable to contours, the material has superior dielectric strength.
  • 800 MHz tuned magnetic sheet absorbers. These are used to line the walls inside cavities to reduce modal resonance. Magnetic sheet absorbers of this kind are commonly applied in enclosed devices. Additionally, the material is ideal for the small chambers that are used for the testing of device emissions.
  • High-loss silicone rubber sheet absorber. Sheet absorbers of the high-loss silicone variety consist of soft material that is cut by razors as well as with die machines. Consisting of silicone rubber, the material has the strength to endure a vast range of temperatures, and it can also withstand the outside elements. Additionally, the material can conform well to curved surfaces due to its thin, elastomeric qualities.
  • Flexible iron/silicone high-loss stock. When it comes to radiofrequency suppression in the aerospace and aviation industry, flexible high-loss stock made from iron/silicone is invaluable for numerous applications, such as for coaxial lines and microstrip circuits. The material is also effective at reducing the cavities and suppressing undesired resonances.
  • High-loss UHF absorber sheet. Another one of the more flexible options in the radiofrequency suppression category is the high-loss UHF absorber sheet, which is also strong enough to endure a range of weather conditions and temperatures. Thanks to the material's ability to conform to complex shapes and bond with metal surfaces, UHF absorber sheets are helpful for custom aerospace industry components.
  • Flexible broadband magnetic sheet absorbers. Made of thin, silicone microwave rubber, this material is applied to the surfaces of metal to reduce radiofrequency currents. Magnetic sheet absorbers of this kind can also be used to modify the pattern of antennas, and it can even serve as an attenuator of transmission lines.
  • Broadband magnetic microwave absorber. A flexible sheet material with the power to absorb over a wide range of angles. Broadband absorber material can handle a range of temperatures and weather conditions. It can also conform to a variety of shapes and surfaces, including metal.
  • Iron loaded epoxies. For curing at room temperature, filled epoxy resins are helpful when it comes to the treatment of components in the aerospace industry. On items that benefits from the use of epoxy resins, the substance provides sufficient coverage.

With custom die cut components for aerospace industry operations, a range of materials are needed to deal with the factors involved in such environments. With their unique qualities, radio suppression materials have helped the industry advance with each new revolution in aerospace engineering, and American Micro Industries has remained on top of these changes for more than 20 years.

Antennas

A vast range of functions are made possible with CNC machining for aerospace industry components. One such range of functions is antenna components, which necessitate the use of high-performance absorbers. The following materials are used for antenna ranges and anechoic chambers, among other things:

  • Weatherproof insertion loss sheets. Antenna component material that's thin and is applicable to substrate contours. While the material doesn't have electrical conductivity, it is strong in the dielectric sense. The softness of the material makes it applicable to both die-cut and razor-cut usage. Made of silicone, the material can endure a range of weather conditions and outdoor elements.
  • Weatherproof microwave absorbers. Thin and flexible, microwave absorber sheets are capable of roping in the vast majority of stray radiofrequencies in an aerospace environment. The material can also endure extreme humidity and freezing situations as well as bond to metal surfaces of varying contour.
  • High-loss magnetic UHF absorber sheets. Microwave magnetic sheets for antenna component applications are thin, ferrite-filled and silicone based, which makes the soft material ideal for die cuts and razor cuts. Offering high UHF magnetic loss, the material is invaluable in the aerospace industry.
  • Lossy carbon-loaded foam sheets. Flexible and lightweight, plastic foam sheets of this variety offer a wide, lossy frequency range. As such, the material is useful in cavities and for purposes such as lowering surface currents, roping in stray radiofrequencies and separating components.

The components produced from custom die cut parts for aerospace industry usage will often require absorber sheets. At American Micro Industries, we help our aerospace clients implement the right solutions for each application.

Contact American Micro Industries for Aerospace Industry Solutions

Out of all the forms of travel, the greatest miracle of human engineering has been aviation. But for humans to travel at such high altitudes, the design and construction of aircraft must be held to the highest possible standards.

At American Micro Industries, we've helped clients from the field develop solutions for custom aerospace industry components for more than 20 years. To learn more about what we can do for your operation, visit one of our services pages.