Aerospace
Aerospace and defence applications demand materials that deliver exceptional performance, reliability, and compliance in the most demanding environments
For over 50 years, Fluorocarbon has supported leading aerospace OEMs and Tier 1 suppliers with high-performance semi-finished materials and precision-engineered components used across commercial aviation, defence, and space programmes worldwide.
Key capabilities include:
- Airbus-approved FL103 glass fibre-filled PTFE to BS6564-3
- Airbus-approved Fluoroetch® sodium/ammonia etching process
- High-performance materials for extreme temperatures and aggressive environments
- Precision-engineered components for sealing, structural, and onboard system applications
- Full traceability and compliance with stringent aerospace quality standards
Aerospace Programmes Typical Requirements
Fluorocarbon supports customers from material selection through to precision manufacturing and full documentation, enabling both new programmes and the ongoing support of legacy platforms.
As an AS9100-certified supplier, we deliver the quality, traceability, and consistency required by the global aerospace industry.
Case Study: Supply Chain Continuity
Material obsolescence can present significant risks for aerospace and defence programmes, particularly when critical components rely on legacy materials with limited supply options.
In one recent project, Fluorocarbon partnered with an aerospace OEM to replace a discontinued TPV material used in injection moulded tube plugs. Our team identified and validated a technically equivalent alternative through a structured engineering change and qualification process, including material evaluation, customer-led validation testing, and FAIR approval.
Following successful qualification, the new material was approved as the material of record, enabling stable production and long-term supply continuity for a mission-critical component.
This project demonstrates how Fluorocarbon supports aerospace and defence customers with material innovation, qualification support, and supply chain resilience.
Aircraft Applications
Operating Environments & Engineering Challenges
Aircraft interiors require materials that balance weight reduction, safety, and durability while operating across fluctuating cabin temperatures and continuous mechanical use.
Our Solutions Include:
- Wear Bushes & Bearing Components for seating mechanisms
- Low-Friction Guides for moving interior assemblies
- Lightweight Structural Support Components
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Cable Management & Routing components
- Sealing Solutions for interior equipment
- Precision-Machined Custom Polymer Parts
Typical Challenges Include:
- Reducing system weight while maintaining structural integrity
- Wear and friction in latches, seating mechanisms, and moving interior parts
- Fire, smoke, and toxicity considerations for cabin materials
- Long service lifetimes with minimal maintenance
Recommended Materials:
- PTFE → Low friction and excellent chemical resistance for moving interior components
- PEEK → High strength-to-weight ratio suitable for lightweight structural components.
- PCTFE → Excellent dimensional stability in sealing applications.
- PFA → High-purity fluoropolymer suitable for demanding interior environments.
Operating Environments & Engineering Challenges
Airframe components must maintain dimensional stability and durability while exposed to vibration, structural loads, and environmental conditions throughout the aircraft lifecycle.
Our Solutions Include:
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PTFE Gaskets & Sealing Solutions for aircraft environmental control systems
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Precision-Machined Polymer Components for Airbus airframe assemblies
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Lightweight Bearing & Wear Components for aircraft structures
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Cable Protection & Routing Components for aerospace systems
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Custom-Engineered Polymer Parts for OEM and MRO requirements
Typical Challenges Include:
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Maintaining seal integrity under vibration
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Dimensional stability across temperature variations
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Lightweight design requirements
- Resistance to corrosion and environmental exposure
Recommended Materials:
- PEEK → High mechanical strength and dimensional stability for structural components
- PTFE → Chemical resistance and stability for interface components and seals
- PCTFE → Dimensional stability and moisture resistance
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F-LON® coating → Enhanced sealing performance
Operating Environments & Engineering Challenges
Engine and fuel system components operate in high-temperature environments with exposure to fuels, lubricants, and pressure variations.
Our Solutions Include:
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PTFE Hose Assemblies for aerospace fluid and thermal management systems
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Fuel-Compatible Sealing Components for engine and fuel system interfaces
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PTFE-Lined Flow Control Components for aerospace fluid handling
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Thermal Insulation & Protection Components for engine environments
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Precision-Machined Polymer Components for propulsion support systems
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High-Performance Gaskets for demanding aerospace operating conditions
Typical Challenges Include:
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Extreme temperature exposure
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Chemical resistance to fuels and hydraulic fluids
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Sealing reliability under pressure and vibration
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Long-term material stability
Recommended Materials:
- PTFE → Outstanding chemical resistance and thermal stability for sealing applications.
- PEEK → High-temperature mechanical strength and durability.
- PCTFE → Low permeability and excellent performance in demanding fluid systems.
- Modified PTFE compounds → Enhanced wear and strength
Operating Environments & Engineering Challenges
Landing gear and actuation systems experience high loads, friction, vibration, and repeated mechanical cycles.
Components must provide reliable performance across demanding operating conditions.
Our Solutions Include:
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PTFE Bushes & Guides for landing gear and actuation mechanisms
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Wear-Resistant Collars & Bearing Components for moving assemblies
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Low-Friction Components for flight control and positioning systems
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Precision-Machined Polymer Parts for aerospace actuation equipment
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Hydraulic System Sealing & Interface Components
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Custom-Engineered Wear Solutions for high-cycle aerospace applications
Typical Challenges Include:
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Wear and friction in moving assemblies
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High cyclic loading and fatigue
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Dimensional stability under load
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Long service life and repeatability
Recommended Materials:
- PTFE → Low friction bearing and wear applications
- Filled PTFE grades → Low friction and improved wear resistance for bearings and guide elements.
- PEEK → Excellent strength and wear resistance in high-load environments.
- PCTFE → Stable performance across temperature ranges
Operating Environments & Engineering Challenges
Defence equipment often operates in harsh and unpredictable environments, including extreme temperatures, exposure to chemicals, vibration, and mechanical shock.
Fluorocarbon materials and components support a wide range of defence systems where reliability, durability, and traceability are essential.
Our Solutions Include:
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Valve Seats & Sealing Components for naval and military fluid systems
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Bearing & Wear Components for defence vehicle suspension and actuation systems
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PTFE Sealing Solutions for fuel and hydraulic equipment
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Guides, Bushes & Collars for military mechanical assemblies
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Low-Friction Wear Components for weapon handling and positioning systems
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Precision-Machined Polymer Parts for mission-critical defence equipment
Typical Challenges Include:
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Wear and friction in moving mechanical assemblies
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Exposure to fuels, hydraulic fluids, and harsh environments
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Vibration and fatigue in mobile or weapon systems
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Long service lifetimes and reliability in mission-critical equipment
Recommended Materials:
- PTFE → Excellent chemical resistance and low friction for sealing systems and wear components.
- PEEK → High mechanical strength and dimensional stability in demanding environments.
- Filled grades of PTFE → Improved wear resistance for bearings, bushes, and guide components.
- PCTFE → Low permeability and stable performance in specialised defence systems
Operating Environments & Engineering Challenges
Space systems require materials capable of performing reliably in extreme environments, including vacuum, radiation exposure, and significant temperature variation.
Our Solutions Include:
- Cryogenic Sealing Components for space propulsion and storage systems
- Vacuum-Compatible Seals for low-outgassing environments
- Bearing & Guide Components for satellite deployment mechanisms
- Low-Permeability Components for cryogenic fluid-handling systems
- Precision-Machined Polymer Parts for spacecraft positioning and control systems
- High-Performance Sealing Solutions for space and research programmes
Typical Challenges Include:
- Extreme thermal cycling
- Cryogenic operating temperatures
- Vacuum compatibility and low outgassing requirements
- Dimensional stability over long mission durations
- Weight reduction for spacecraft efficiency
- Reliability in inaccessible operating environments
Recommended Materials:
- PCTFE → Excellent dimensional stability and low permeability, suitable for cryogenic and vacuum environments.
- PTFE → Outstanding temperature resistance and chemical stability for seals and interface components.
- PEEK → High strength-to-weight ratio and excellent mechanical performance in demanding aerospace applications.
- Modified Fluoropolymer Grades → Enhanced performance for specialised space applications
Case Study: Engineering Low-outgassing Coatings for Vacuum Tribology in Space Applications
A European space technology company requested a PTFE coating for aluminium components operating in vacuum conditions, where very low outgassing, stable friction behaviour, and predictable coating performance were essential to system reliability.
The combination of vacuum constraints, material pairing, and performance expectations meant a standard coating system could not be recommended
without first resolving fundamental material and process trade-offs.
The requirement set effectively eliminated conventional approaches and demanded a structured engineering evaluation.
