structural foam molding
TRANSCRIPT
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STRUCTURAL FOAM MOLDING
AND SANDWICH MOLDING
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INJECTION MOLDINGTo produce the parts by injecting a material.
Performed with metals, , thermoplastic and thermosetting polymer.
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STRUCTURAL FOAM MOLDINGlow pressure injection molding inert gas into the melted polymerReduces density and weightIncreases strength
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Materials usedThermoplastic material:
•Polycarbonate•ABS•Polyphenylene oxide-PPO•Polybutylene terephthalate
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Design Benefits Reduced part weightThick sections up to 5 inchesLower cost toolingChemical and corrosion resistance
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Performance BenefitsIncreased strength to weight ratioChemical and corrosive resistanceImproved acoustical and electrical insulation characteristicsCan be recycled and reused.
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APPLICATIONS•Tool boxes•Trash cans•Commercial laundry bins•Pallets•Replace wood,concrete,metals,fiberglass
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SANDWICH MOULDINGTwo or more polymers are injected one after another through the same gate in one or more cavities.Core and skin material different or same.Also called as co-injection molding
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PROCESSINJECTION 1-FORM THE SKIN MATERIAL
INJECTION 2- FORM THE CORE
INJECTON 3-TO SEAL THE GATE AND FINISH THE PART
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PROPERTIES OF SKIN MATERIAL
Will be thin Surface structure of the material.Transparent materialPaintable surfaceE.g.: glass, thermoplastics,
thermosets , sheet material , plywood
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PROPERTIES OF CORE MATERIAL
Thick but will be lightweight.Low density materialHigh bending stiffness.Recycled material.E.g. :PVC, polyethylene ,polystyrene ,
metal foams.
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APPLICATIONS
•Door handles in car industry(strengthening)
•Electronic housings•Decks in ships•In aerospace, making doors in airplane•Antennas
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METHODS:Autoclave moldingAdhesive bondingLiquid moldingContinuous lamination Compression molding