Case Studies

Alpine’s revolutionary materials have been tested by major aeronautics and defense organizations whose performance standards are among the most rigorous in the world. Our materials have been used in the manufacture of components for jet fighters, high-speed helicopters, amphibious transport vehicles, missiles, rockets, and satellites.

Missile Bracket

MISSILE BRACKET

  • Legacy part was machined aerospace grade aluminum (6061 T6)

  • Extremely time-consuming to machine with multiple set-ups

  • Required significant fixturing

  • Required secondary post-processing operations to stress relieve the part

HX5 RESULTS

  • 50% weight of aluminum

  • Significant production cycle time reduction (min/part)

  • No post-processing or chemical surface treatments

  • Simplification of supply chain

missile bulkheadmissile bulkhead

MISSILE BULKHEAD (10” DIAMETER)

  • Complicated design, low volume (10 parts required)

  • HX5 preform quickly molded with oversized aluminum tool ($3K vs typical $35k)

  • HX5 preform machined to clean-up to specified dimensions

  • Holes drilled, chamfered and tapped

HX5 RESULTS

  • 50% weight reduction

  • Attractive tooling/part cost reduction due to low-cost near-net-shape mold tooling cost

electronic enclosures

ELECTRONICS ENCLOSURE FOR ROTORCRAFT APPLICATION

  • Legacy design was machined aerospace grade aluminum (6061 T6)

  • HX5 components were molded, drilled, tapped and assembled as required

  • HX5 was metallized for EMI shielding and grounding requirements

HX5 RESULTS

  • 45% weight reduction

  • Improved cooling efficiency due to greater compartmental air flow

  • Significant product cycle time reduction (min/part)

  • Simplification of supply chain

Missile Bracket

Gunner Chair

  • Legacy baseline chair was mostly steel

  • Complicated design with 150 parts

  • Heavy structure, weighing approx. 110 lbs

HX5 RESULTS

  • Replaced the 150-piece steel structure with a two-piece HX5 support structure

  • 75% weight savings

  • Advanced manufacturing allows production of up to 100 seat structures per day

Missile Bracket

Payload Fairing (PLF)

  • Payload fairings (PLF) are expensive aerodynamically loaded structures

  • Legacy part is typically composite, aluminum or spruce

  • Complex design details, attachments, and fittings

  • Production rates are weeks to months

HX5 RESULTS

  • 40 Payload Fairings molded in two working days (15 minutes per part)

  • 99% schedule reduction

HX5

AT A GLANCE

$50 + M & 8 YEARS

invested in the research and development of HX5

90%

strength of 6061 aluminum

50%

weight of 6061 aluminum

Survives

extreme environmental conditions

Passed a

Military

16g crash test

Meets

Aerospace

Standards

Analysis of HX5 usage demonstrates significant weight reduction, much greater resistance to extreme environmental conditions, performance improvements, and speed-to-market advantages for a wide range of applications.

MECHANICAL PROPERTIES

HX5 has 90% the strength AND near 50% the density of 6061 T6 aluminum

Mechanical Properties ASTM HX5 (73˚F) 6061 T6 (73˚F)
Tensile Strength, (Ksi) D638 38.2 40
Density, (lbs./ft3) D792 89 169
Specific Strength, (lb/in2)/(lb/in3)​ 741,700 410,300

THERMAL PROPERTIES

HX5 is dimensionally stable at elevated temperatures

Thermal Properties ASTM HX5 6061 T6
Coefficient of Thermal Expansion, (L/L/°F) E 831 2.11 X 10-6 13.1 X 10-6

ENVIRONMENTAL STABILITY

HX5 is engineered to survive

  • Meets rigorous DoD guidelines for flame, smoke, and toxicity

  • Extremely resistant to solvents, fuels, lubricants, and chemicals

  • Satisfies NASA spacecraft limits on outgassing and radiation resistance stability (doesn’t degrade in space)

  • High temperature capable

  • Passed accelerated lifetime thermal cycling and high-temperature thermal stability

  • Galvanic corrosion resistant

MANUFACTURABILITY

Engineered to be versatile

  • Drop-in material for many injection molding operations

  • Low shrinkage and excellent dimensional stability (0.5% vs. 2.0%)

  • Enables part consolidation into a single molded component

  • Compatible with metallic insert molding operations for multifunction products

  • One material formulation compatible with many manufacturing operations:

    • Injection molding
    • Profile extrusion
    • Compression molding
    • Thermoforming

SECONDARY OPERATIONS

HX5 is engineered to process like a metal

  • Machines like aluminum without chipping, cracking, galling or gumming

  • Taps and threads like metal

  • Unlike most solvent resistant materials, can be coated, primed, painted and adhesively bonded

  • Can be metallized to meet EMI shielding requirements

MECHANICAL PROPERTIES

HX5 has 90% the strength AND 50% the weight of 6061 T6 aluminum

Mechanical Properties ASTM HX5 (73˚F) 6061 T6 (73˚F)
Tensile Strength, (Ksi) D638 38.2 40
Density, (lbs./ft3) D792 89 169
Specific Strength, (in) 741,700 410,300

THERMAL PROPERTIES

HX5 is dimensionally stable at elevated temperatures

Thermal Properties ASTM HX5 6061 T6
Coefficient of Thermal Expansion, (L/L/°F) E 831 2.11 X 10-6 13.1 X 10-6

ENVIRONMENTAL STABILITY

HX5 is engineered to survive

  • Meets rigorous DoD guidelines for flame, smoke, and toxicity

  • Extremely resistant to solvents, fuels, lubricants, and chemicals

  • Satisfies NASA spacecraft limits on outgassing and radiation resistance stability (doesn’t degrade in space)

  • High temperature capable

  • Passed accelerated lifetime thermal cycling and high-temperature thermal stability

  • Galvanic corrosion resistant

MANUFACTURABILITY

Engineered to be versatile

  • Drop-in material for many injection molding operations

  • Low shrinkage and excellent dimensional stability (0.5% vs. 2.0%)

  • Enables part consolidation into a single molded component

  • Compatible with metallic insert molding operations for multifunction products

  • One material formulation compatible with many manufacturing operations:

    • Injection molding
    • Profile extrusion
    • Compression molding
    • Thermoforming

SECONDARY OPERATIONS

HX5 is engineered to process like a metal

  • Machines like aluminum without chipping, cracking, galling or gumming

  • Taps and threads like metal

  • Unlike most solvent resistant materials, can be coated, primed, painted and adhesively bonded

  • Can be metallized to meet EMI shielding requirements