PEEK GF30 Structural Spacer Bracket for Aerospace

The requirement

An aerospace equipment supplier needed a structural spacer bracket with mounting holes that would hold its position accuracy over a long production run, at a lower weight than the metal spacer it had used before.

The challenge

Glass filler is highly abrasive and wore tools quickly, causing batch-to-batch dimensional drift. The asymmetric geometry deformed once the fixture was released.

Our approach

PCD tooling as standard for GF30, staged machining with stress-relief cycles, and temporary supports removed only in the final operation.

Five steps from drawing to delivery

1. DFM review and material plan — The asymmetric geometry and the glass-fibre content were reviewed before the programme was planned, and PEEK GF30 confirmed against the weight and stiffness requirement.
2. Fixturing, tooling and programming — PCD tooling specified as standard for GF30, because the glass filler is highly abrasive and would wear carbide quickly.
3. Rough and finish machining — Staged machining with stress-relief cycles between the stages. The temporary supports that held the asymmetric shape were removed only in the final operation, so the part was never released from fixturing while deformed.
4. In-house inspection — Hole position accuracy on the Zeiss SPECTRUM CMM, checked against the drawing datum scheme across the run rather than only at first article.
5. Documentation and delivery — Batch traceability and material certificates per production lot, so a long-running programme stays auditable.