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High Performance Thermoplastic Composites for Medical Applications

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Presentation on theme: "High Performance Thermoplastic Composites for Medical Applications"— Presentation transcript:

1 High Performance Thermoplastic Composites for Medical Applications
Cutting Dynamics Avon OH May 29, 2013

2 Why Thermoplastic Composites?
High strength, stiffness, lower weight vs metallic components Maintains high precision tolerances through numerous autoclave sterilizations Radiolucent Tough, durable, excellent fatigue resistance Shape has the potential to be tailored on site if needed Green, recyclable product Excellent chemical resistance

3 Continuous Compression Molding
Process Lay up tape in predetermined orientation Process thru CCM flat machine- 24” wide max Process thru CCM Shape Machine-5 x 5 sq max Cut on 5 axis, WJ or Robot

2-step or 2D process 1-step or 1D process

5 Stamp Forming Process Description Material Layup- manual or FF
Continuous Compression Mold-Flat-24” wide Stamp Form in Press- 40” x 48” Trim on 5 axis WJ or machine Type Lay-up of multiaxial panels Full automatic process control Maximum part size 40" x 40" Maximum speed 5 minutes/part Maximum thickness not limited Status in Service

6 3-Dimensional Stamp Forming Process
Full automatic process control Nominal compression force 4000 kN Maximum width 40" Maximum part size 28" x 40" Maximum speed 5 minutes/part Maximum temperature 752 °F Maximum thickness 0.2" Capacity 3-shift 8,500 parts/year (5 minutes/part) Status in Service Production unit for 2D and 3D stamp forming Medium parts

7 5 Axis Robotic Trimming

8 Profile Machine Maximum width 4" (100 mm)
Maximum Cross section 4" x 4" (100x100 mm) Maximum feed 150 ft/h (30 m/h) Maximum temperature 770 °F (410 °C) Maximum thickness 0.4"(10 mm)

9 Prototype and Series Production of CCM Parts

10 Typical Weight Reduction Application
These typical parts could be made from one CCM then smaller parts removed then trimmed and formed. lb alum 2.366 lb CCM weight 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” long 40% Fiber, 60% PPS 70-80% of strength of uni- tape Add 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 Process Enhanced Properties vs Injection Molding Incorporation of Complex Features Without Subsequent Machining Lower Cost Metal Replacement Opportunities for Reduced Weight

13 Injection Molding Properties
Metal-like Properties Can be Achieved with Novel TP Matrix Material Tensile Strength (ksi) Density (g/cc) Steel 58 7.8 Standard PES 13.6 1.35 30% GF PES 25 1.58 CDI Modified PPS 40 Weight and cost reductions vs metal and compression molded parts

14 Summary Thermoplastic Composites are demonstrated, high performance materials for medical applications Lightweight, high performance radiolucent material Maintains precision tolerances through numerous sterilizations High temperature usage Wide variety of forms available We are interested in working on support and development of medical applications.

15 Thank you! Michael Favaloro Sales Manager
For more information, please contact: Michael Favaloro Sales Manager Phone: Bill Carson President Phone: Fax: Cutting Dynamics, Inc. 980 Jaycox Road Avon, OH 44011

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