HexAM® Additive Manufacturing and Aftermarket Applications

Product catalog summary

Introduction
Hexcel’s HexAM® additive manufacturing process utilizes high-performance thermoplastic combined with selective laser sintering (SLS) technology to produce HexPEKK® components. These parts offer significant reductions in weight, cost, and time-to-market compared to traditional metal or composite technologies, while maintaining consistent engineering material properties.

Superior Material

HexAM® combines PEKK thermoplastic with aerospace-grade carbon fiber fill.
Fully qualified by organizations such as America Makes, AFRL, NASA, Northrop Grumman, and Boeing.
Excellent performance in flammability, outgassing, smoke/toxicity.
Service temperature of ±300˚F, suitable for metallic/composite replacement.
Melt temperature of 600˚F, with specific strength similar to cast aluminum.
Compatible with common aerospace fluids and offers significant weight savings due to its density being half that of cast aluminum.

Superior Process

Allows for assembly consolidation with multiple components sintered as a single piece.
Part geometry complexity does not affect cost.
SLS process enables production of a large quantity of components in a single chamber.

Benefits

No tooling required, reducing cost and lead time.
No touch labor required, making it faster than conventional machining.
Engineering changes do not necessitate rework/redesign of tooling.
Potential for optimization with improved weight savings and performance based on organic shapes.

Production Solutions for Aftermarket Components
HexAM® is suitable for low-rate customization parts and quick replacements of casting and composite ducts. HexPEKK® parts are ideal for drop-in replaceable, cost-competitive hardware.

Production Quality and Rapid Manufacturing

AS9100 certified and OEM supplier.
Qualified to BMS 8-401, BAC5692 standards.
Tooling-free fabrication with competitive pricing from custom needs to serial production.
Supports legacy platforms through reverse engineering and printing hardware.
Enables part consolidation and production of high complexity ducts.
Paintable surfaces for aesthetic or performance considerations.

Catalog excerpts

HexAM® Additive Manufacturing and Aftermarket Applications-1

HexAM® Additive Manufacturing Title Subtitle and Aftermarket Applications Hexcel’s HexAM® additive manufacturing process combines high-performance thermoplastic with selective laser sintering (SLS) technology to produce fully functional HexPEKK® end-use components. HexPEKK® parts offer significant weight, cost and time-to-market reductions compared to incumbent metal or composite technologies while providing repeatable and validated engineering material properties. Superior Material Superior Process ¥¥Assembly consolidation, multiple components sintered as a single piece ¥¥Complexity of part geometry does not affect cost ¥¥SLS (powder bed) process allows for large quantity of components in a single chamber approximately 660mm x 356mm x 534mm Benefits ¥¥HexAM® additive manufacturing combines a high-performance PEKK thermoplastic with an aerospace-grade carbon fiber fill ¥¥Fully qualified through America Makes, AFRL, NASA, Northrop Grumman and Boeing ¥¥Excellent flammability, outgassing, smoke/toxicity performance ¥¥Service temperature: ±300˚F – appropriate metallic/composite replacement ¥¥600˚F melt temperature ¥¥Similar in specific strength to cast aluminum ¥¥Compatible with all common aerospace fluids ¥¥Density half of cast aluminum – excellent weight savings tooling required – lowers cost and lead time ¥¥No touch labor required – quicker process than conventional machining ¥¥Engineering changes do not require rework/redesign of tooling ¥¥Optimization potential – improved weight

Open the catalog to page 1

HexAM® Additive Manufacturing and Aftermarket Applications-2

Production solutions for aftermarket components HexAM® additive manufacturing is ideal for anything from low-rate customization parts to quick replacements of casting and composite ducts. HexPEKK® 3D-printed parts are the material of choice for drop-in replaceable, cost-competitive hardware. Production Quality, Rapid Manufacturing Digital Definition free fabrication ¥¥Competitive pricing from custom needs through to serial production ¥¥Support legacy platforms by reverse engineering and printing hardware Ducts, Closeouts and Brackets Casting Replacements consolidation ¥¥High complexity ducts...

Open the catalog to page 2