Egmond Plastic is the global specialist in the area of fusible core injection moulding in combination with Peek material with carbon reinforced fibres. This technology makes it possible to mould inject complicated hollow parts all at one time, without the need for welding. With more than 20 years of experience in fusible core injection moulding for the aerospace industry, this type of production technology has been used for the fuel system components for military and civil aircrafts. The advantages are very obvious; 50% weight reduction as well as a possible 30% cost reduction.

The manufacturing of a scroll for the air cycle machine would be a next step for fusible core injection moulding technology. No company offered the scroll in thermoplastic material. This program identified, designed, and manufactured a scroll made from thermoplastic material (Peek with reinforced carbon fibres), using a fusible core. This program demonstrated the use of thermoplastic material for this application and proved that considerable gains are to be expected when making the scroll from thermoplastic material.

The expected impact of the program was large. For Clean Sky, considerable weight savings were expected, resulting in lower emissions and improved performance. From a technical point of view, it is the next step in technology change for the air cycle machine and it might lead to possible other components to be replaced with a thermoplastic material. From Egmond Plastic, this program provided an opportunity to become the world class leader of fusible core technology for the aerospace industry.