UHMWPE - Lightweight Advanced Aircraft Materials and Manufacturing

Innosek has teamed up with The University at Buffalo, to research the feasibility of using additive manufacturing to create lightweight aircraft components made of ultra-high molecular weight polyethylene (UHMWPE). The University at Buffalo had previously been developing a method to treat UHMWPE, making it 14x stronger and 8x less dense than carbon steel. They will further their research by adapting the polymer for use in structural components, and testing functionality over a broad temperature range, mimicking the temperatures of aircraft operating conditions. Innosek will seek Air Force stakeholders for a successful STTR Phase II Memorandum of Understanding (MOU), as well as test the feasibility of 3D printing UHMWPE. Prior studies have shown that additive manufacturing of UHMWPE is possible, but optimization features must be implemented. Innosek aims to create an enhanced thermally controlled environment within a selective laser sintering (SLS) instrument to commercialize additive manufacturing of UHMWPE. Anticipated benefits are the development of lightweight structural eVTOL components manufactured at lower cost, provide lower cost per mile, and with better protection against physical threats. Potential commercial applications range from automotive structural components to sports protective equipment and additively manufactured custom orthopedic implants.