CREATING STRUCTURAL IMPACTHOLLOW COMPOSITE TOOLING

February 2019

INTRODUCTIONCOMPOSITE TOOLING

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Key drivers Weight reduction Design freedom CO2 reduction

Lightweight materials and design have always been an important topic in product design across several industries. The concept has been most important in aviation and also in automotive, where driving dynamics are a major consideration. Global trends toward CO2 reduction and resource efficiency have significantly increased the importance of this topic over the last years.

Fiber-reinforced plastics are a unique solution for engineers in aerospace, automotive and sporting goods because of their incredible strength-to-weight ratio. The combination of fibers and polymer form a new material with improved physical properties.

APPLICATION AREASCOMPOSITE TOOLING

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Aerospace Automotive Marine

COMPOSITE TOOLINGINDUSTRY CHALLENGES

Whether your application requires reusable layup mold tooling or sacrificial tooling for complex, trapped-tool geometries, Additive Manufacturing simplifies the fabrication of composite parts while provided unparalleled design freedom. High temperature, cost effective tools can be produced in days, compared to the weeks or even months required for traditional tooling.

Industry drivers Reduce cost and leadtime Produce (small series) functional products Respond quickly to customer demands

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HOLLOW COMPOSITESINDUSTRY CHALLENGES

While basic shapes with constant cross sections are easily manufactured using traditional composite manufacturing techniques, complex composite parts with hollow interiors present a unique manufacturing challenge. Any configuration that traps a core or mandrel inside requires sacrificial tooling.

Industry drivers Design freedom to create any hollow composite shape Create smooth internal and external composite surfaces Reduce turn around time from design to part Provide a cost effective solution for small series

production

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Additive manufacturing has fundamentally changed the procedure for creating complex, hollow composite parts.

Offers significant design freedom and the ability to quickly iterate designs

Create smooth internal carbon surfaces & higher fine feature definition

Eliminates the need for additional tooling or molds for sacrificial tool production

Low initial investment required to create small series productions

ADDITIVE MANUFACTURINGTECHNOLOGY BENEFITS

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MAKING ALL THE DIFFERENCEHOLLOW COMPOSITE PROCESS

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DSM provides an efficient and cost-effective approach for producing tough, complex hollow composite parts with a superb surface finish and high feature detail compared with competing technologies.

Using DMX/NeXt to offer a sacrificial, flexible and airtight core which has the unique feature to be easiest and best removed, after the autoclave process, from convoluted shapes and voids, in the industry.

This method of using additive manufacturing to produce sacrificial tooling is straightforward and enables multiple iterations to be implemented quickly by the user.

HIGHLIGHTS

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SOMOS® DMX / SOMOS® NEXT

“DMX 100 OFFERS AN UNPARALLELED SOLUTION FOR COMPLEX HOLLOW COMPOSITE PARTS ACROSS A WIDE RANGE OF INDUSTRIES.“

Jonathan WarbrickGraphite AM (UK)

VISUAL, OPTICAL & MECHANICAL PROPERTIESPRODUCT DETAILS

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Mechanical properties DMX (Metric) DMX (Imperial) NeXt (Metric) NeXt (Imperial)Tensile Strength @ Yield (UV Postcure) 44.8 MPa 6.5 ksi 42.2 Mpa 6.1 ksi

Tensile Strength @ Break (UV Postcure) 30.9 MPa 4.5 ksi 32.8 Mpa 4.8 ksi

Ultimate Tensile Strength (UV Postcure) 45 Mpa 6.5 ksi 42 Mpa 6.1 ksi

Elongation @ Break (UV Postcure) 20% 9%

Elongation @ Yield (UV Postcure) 4% 3%

Young's Modulus (UV Postcure) 2410 Mpa 350 ksi 2430 Mpa 352 ksi

Poisson's Ratio (UV Postcure) 0.41 0.41 0.43 0.43

Flexural Strength (UV Postcure) 68 Mpa 9.9 ksi 69.3 Mpa 10.1 ksi

Flexural Modulus (UV Postcure) 2290 Mpa 332 ksi 2470 Mpa 358 ksi

Izod Impact -Notched (UV Postcure) 66 J/m 1.23 ft-lb/in 50 J/m 0.94 ft-lb/in

Hardness - Shore D (UV Postcure) 80 82

Water Absorption (UV Postcure) 0.84% 0.4%

Visual properties DMX NeXtAppearance Off-white White

Viscosity 1500 cps @ 30 °C 1000 cps @ 30 °C

Density 1.17 g/cm3 @ 25 °C 1.17 g/cm3 @ 25 °C

Optical properties DMX NeXtCritical Exposure (Ec) 15 mJ/cm2 12 mJ/cm2

Slope of Cure Depth (Dp) 5.5 mils 5.8 mils

Exposure for 0.01" Thickness (E10) 92 mJ/cm2 67 mJ/cm2

THERMAL PROPERTIESPRODUCT DETAILS

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Thermal properties DMX (Metric) DMX (Imperial) NeXt (Metric) NeXt (Imperial)C.T.E. -40 to 0 °C (-40 to 32 °F) (UV Postcure) 84.5 µm/m °C 47 µm/in °F 73 40.6 µm/in °F

C.T.E. 0 to 50 °C (32 to 122 °F) (UV Postcure) 129 µm/m °C 71.7 µm/in °F 111 61.7 µm/in °F

C.T.E. 50 to 100 °C (122 to 212 °F) (UV Postcure) 183.3 µm/m °C 101.9 µm/in °F 172 95.6 µm/in °F

C.T.E. 100 to 150 °C (212 to 300 °F) (UV Postcure) 179.2 µm/m °C 99.6 µm/in °F 173 96.2 µm/in °F

C.T.E. before Tg (44 °C) (UV Postcure) µm/m °C µm/in °F µm/m °C µm/in °F

C.T.E. after Tg (44 °C) (UV Postcure) µm/m °C µm/in °F µm/m °C µm/in °F

Dielectric Constant 60 Hz (UV Postcure) 4.3 4.7

Dielectric Constant 1 kHz (UV Postcure) 3.9 4

Dielectric Constant 1 MHz (UV Postcure) 3.7 3.6

Dielectric Constant and Dissipation Factor 1 kHz (UV Postcure) k D k D

Dielectric Strength (UV Postcure) 15 V/mm 381 V/mil 15.2 V/mm 386V/mil

HDT @ 0.46 Mpa (66 psi) (UV Postcure) 44 °C 111 °F 56 °C 133 °F

HDT @ 1.81 Mpa (264 psi) (UV Postcure) 41 °C 106 °F 50 °C 122 °F

Thermal Conductivity NA NA

Electrical Conductivity NA NA

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