Presentation on theme: "High Performance Thermoplastic Composites for Medical Applications"— Presentation transcript:
1 High Performance Thermoplastic Composites for Medical Applications Cutting DynamicsAvon OHMay 29, 2013
2 Why Thermoplastic Composites? High strength, stiffness, lower weight vs metallic componentsMaintains high precision tolerances through numerous autoclave sterilizationsRadiolucentTough, durable, excellent fatigue resistanceShape has the potential to be tailored on site if neededGreen, recyclable productExcellent chemical resistance
3 Continuous Compression Molding ProcessLay up tape in predetermined orientationProcess thru CCM flat machine- 24” wide maxProcess thru CCM Shape Machine-5 x 5 sq maxCut on 5 axis, WJ or Robot
4 CONTINUOUS COMPRESSION MOULDING MECHANICAL DEPICTION 2-step or 2D process1-step or 1D process
5 Stamp Forming Process Description Material Layup- manual or FF Continuous Compression Mold-Flat-24” wideStamp Form in Press- 40” x 48”Trim on 5 axis WJ or machineType Lay-up of multiaxial panelsFull automatic process controlMaximum part size 40" x 40"Maximum speed 5 minutes/partMaximum thickness not limitedStatus in Service
6 3-Dimensional Stamp Forming Process Full automatic process controlNominal compression force 4000 kNMaximum width 40"Maximum part size 28" x 40"Maximum speed 5 minutes/partMaximum temperature 752 °FMaximum thickness 0.2"Capacity 3-shift 8,500 parts/year(5 minutes/part)Status in ServiceProduction unit for 2D and 3D stamp formingMedium parts
10 Typical Weight Reduction Application These typical parts could be made from one CCM then smaller parts removed then trimmed and formed.lb alum2.366 lb CCMweight savings X 2 (RH + LH)Use click-bond & delete rivets
11 3D Molded Shapes Extrusion of IM7 reclaimed and Pure PPS Fibers are Random- ½” to 1” long40% Fiber, 60% PPS70-80% of strength of uni- tapeAdd unidirectional tape in areas of high stress for additional strength
12 Injection Molding and Overmolding Continuously Reinforced Components Can be Enhanced with Detailed Features by the Injection Overmolding ProcessEnhanced Properties vs Injection MoldingIncorporation of Complex Features Without Subsequent MachiningLower CostMetal Replacement Opportunities for Reduced Weight
13 Injection Molding Properties Metal-like Properties Can be Achieved with Novel TP MatrixMaterialTensile Strength (ksi)Density (g/cc)Steel587.8Standard PES13.61.3530% GF PES251.58CDI Modified PPS40Weight and cost reductions vs metal and compression molded parts
14 SummaryThermoplastic Composites are demonstrated, high performance materials for medical applicationsLightweight, high performance radiolucent materialMaintains precision tolerances through numerous sterilizationsHigh temperature usageWide variety of forms availableWe are interested in working on support and development of medical applications.
15 Thank you! Michael Favaloro Sales Manager For more information, please contact:Michael FavaloroSales ManagerPhone:Bill CarsonPresidentPhone: Fax:Cutting Dynamics, Inc.980 Jaycox RoadAvon, OH 44011
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