New process cuts prototype lead times in half, helping customers move faster from concept to testing

Greene Tweed has developed a rapid prototyping process for its Xycomp DLF material that helps aerospace customers accelerate metal replacement development projects through faster testing and validation. The process reduces lead times and costs, expanding access to high-performance composites in new markets, including Advanced Air Mobility (AAM) and Defense.

Xycomp DLF components are high-performance thermoplastic composites engineered to replace metals while delivering weight savings, stiffness, and strength. The new process cuts prototype lead times by nearly 50% compared to traditional production methods through a proprietary approach that optimizes the tool design and balance between machine and net-molded features, while maintaining production-representative material and part properties. The result is quicker access to functional parts, with lower upfront tooling costs and greater design flexibility before production.

Key innovations behind Greene Tweed’s rapid prototyping breakthrough include:

• Optimised Mould Design: A balance of machined and net-moulded features reduces tooling complexity and speeds up production.
• Streamlined Parallel Processes: Completing part, tool, and fixture designs concurrently significantly compresses timelines.
• In-House Expertise: A hands-on approach ensures precision and quality, with mould fit-ups completed in one to two days.
• Rapid, Low-Cost Iteration: Customers can test, refine, and optimise components through phased evaluations with lower cost, readily modifiable tools.

Rapid prototyping is helping expand composite adoption across aerospace, AAM, defense, mobile robotics, and energy as demand grows for lightweight, durable components. In AAM, customers are using Xycomp DLF components for lightweight, custom-engineered electric vertical take-off and landing (eVTOL) applications, with rapid design iteration and close technical collaboration between customers and Greene Tweed engineers fast-tracking the path from concept to reality.