Xycomp® DLF Composites

Xycomp® DLF is a lightweight thermoplastic composite developed to replace complex-shaped metal components. With outstanding fatigue, vibration, and impact resistance, it provides up to 50% weight savings.

Xycomp® DLF is produced from aerospace-grade, carbon-fiber-reinforced, unidirectional prepreg tape which is chopped into flakes, resulting in high fiber content (60% by volume / 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.

Make sure to watch the video on the right-hand side of the page and click the "View Downloads" button at right to access a case study on a collaborative development effort between Greene Tweed and a major aerospace engine manufacturer, proving the suitability of DLF brackets for production service on commercial aircraft engines.