Aerospace plastic components demand more than a capable molding machine. They require material traceability, repeatable dimensions, controlled processing, and documentation that can stand up to an audit. For a Tier 1 aerospace supplier, HWPD produced PEEK connector housings to a ±0.02 mm tolerance with 100% CMM inspection and a complete quality package.
The connector housing included thin walls, precision bores, and several datum features that controlled downstream assembly. Before tooling, HWPD reviewed the drawing, GD&T scheme, and inspection method. The team recommended clarifying one profile tolerance and separating cosmetic requirements from functional datums. This allowed the mold and inspection plan to target the dimensions that mattered most.
PEEK processing requires stable drying, high melt temperature, and a tool designed for elevated thermal conditions. The mold used hardened steel in high-wear areas and replaceable inserts around the connector features. Cooling was balanced to reduce differential shrinkage, while the ejection system was kept clear of the sealing and datum surfaces. This is the type of preparation expected from a specialist injection mold manufacturer.
During sampling, the parts were measured in a controlled environment after conditioning. A small variation was found across one bore position. Instead of relying on a process adjustment alone, HWPD compared the CMM data with mold temperature and gate-freeze behavior. The insert was corrected and the process window was tightened. Subsequent samples met the drawing requirements across the complete dimensional report.
The inspection plan covered incoming resin verification, first-piece approval, in-process checks, and final CMM measurement. Each batch was linked to material certificates and production records. HWPD also prepared a documentation package that supported the customer’s AS9100 audit without a single nonconformance report.
The program shows why aerospace molding must begin with engineering clarity. A precise part is the result of aligned drawings, stable material preparation, robust tooling, and objective inspection. HWPD’s approach connects those activities so that quality evidence is available when the customer needs it, not reconstructed after production.