overmolding with polystrand™ continuous fiber reinforced

PROCESS OVERVIEW

Polystrand™ advanced thermoplastic composites combine high strength, unidirectional, continuous fibers with engineered thermoplastic resins to create continuous fiber reinforced thermoplastic (CFRTP) materials that feature exceptional strength-to-weight ratio and high impact resistance.

Overmolding integrates Polystrand tapes and multi-ply laminates into traditional thermoplastic molding processes, such as injection and compression molding, to create locally-reinforced, molded components.

Improve performance, enhance your capability

• Meet higher performance requirements with thermoplastic materials

• Reduce part weight• Achieve rapid cycle times• Differentiate with expanded manufacturing

and product performance capabilities

Dramatically increasing impact resistance and stiffness of molded components—without adding significant weight—means that OEMs can meet increasingly demanding application requirements. For molders, incorporating CFRTP overmolding capabilities expands their product offering, opening the door for increased market share.

Overmolding with Polystrand™ Continuous Fiber Reinforced Thermoplastic CompositesProcessability Meets Performance

Overmolding with Polystrand

CFRTP can enhance the

performance of traditional

thermoplastics or enable

metal replacement in a wide

range of applications.

Read the Rome Snowboard Binding

Case Studybit.ly/34PG0a6

http://bit.ly/34PG0a6





Incorporating Polystrand

CFRTP reinforcement in

molded thermoplastic

components combines

the design flexibility

and fast cycle times of

traditional molding with

the strength, stiffness,

and lightweighting

benefits that composites

offer, all with the use

of standard processing

equipment.

OVERMOLDING WITH POLYSTRAND CFRTP

INJECTION/COMPRESSION MOLDING

• Design flexibility• Complex shapes• Fast cycle times

POLYSTRAND CFRTP

• Impact resistance• Strength & stiffness• Light weight

PROCESS DESCRIPTION

Polystrand CFRTP materials are integrated into the molding process in a few simple steps, allowing you to add lightweight, localized reinforcement without compromising cycle times or shape complexity.

Injection Moldable Polymer

CFRTP Blank

Auxiliary Heater

Overmolded Finished Part

Increase strength and impact resistance. Enable thinner, lighter part design.

Mold to compress and cool into shape

4

CFRTP is preheated and inserted into tool

3Material heating,

melting, and conveying

2Solid resin infeed

1

5

ON-ROAD TRANSPORTATIONUnderbody shields, underhood enclosures, interior components, storage

OFF-ROAD VEHICLESSkid plates, doors, seat structures, exterior panels & moldings

Traditionally, molding with short and long glass-filled polypropylene to gain flexural performance over unfilled polypropylene also results in a loss of impact resistance. As illustrated here, molding with continuous fiber reinforced composites enables improved flexural performance over filled polypropylene as well as increased impact resistance and overall weight reduction. The result? Game-changing design freedom achieved through improved stiffness and strength combined with thinner, lighter part design.

With a single layer of Polystrand CFRTP:

• Flexural strength increases more than 60%

• Total energy absorbed on impact improves by nearly 35%

• Peak force at puncture increases

over 58%

Increase strength and impact resistance. Enable thinner, lighter part design.

SPORTING GOODSBoots, bindings, protective equipment

MARINEHull reinforcement,seats, paddles

50% Long Glass Fiber Reinforced

PP


PP + 0° CFRTP

50% Long Glass Fiber Reinforced PP + 0°/90°

CFRTP


PP + 0°/90°/90°/0°

CFRTP

17K 28K 29K


PP + 0°/90°/0° CFRTP

29K 31K

+60.7%

FLEXURAL STRENGTH (ASTM D7264)

IMPACT RESISTANCE (ASTM D3763)


PP


PP + 0° CFRTP


CFRTP


PP + 0°/90°/0° CFRTP


PP + 0°/90°/90°/0°

CFRTP

Ene

rgy

at T

otal

(J)

Forc

e at

Pea

k (k

N)

18

16

14

12

10

8

6

4

2

0

6.0

5.9

4.0

3.0

2.0

1.0

0.0

11.2 15.1 14.6 12.7 16.4

1.2 1.9 2.8 4.0 5.0

+58.3%

+34.8%


PP


PP + 0° CFRTP


CFRTP


PP + 0°/90°/90°/0°

CFRTP

17K 28K 29K


PP + 0°/90°/0° CFRTP

29K 31K

+60.7%

FLEXURAL STRENGTH (ASTM D7264)

IMPACT RESISTANCE (ASTM D3763)


PP


PP + 0° CFRTP


CFRTP


PP + 0°/90°/0° CFRTP


PP + 0°/90°/90°/0°

CFRTP

Ene

rgy

at T

otal

(J)

Forc

e at

Pea

k (k

N)

18

16

14

12

10

8

6

4

2

0

6.0

5.9

4.0

3.0

2.0

1.0

0.0

11.2 15.1 14.6 12.7 16.4

1.2 1.9 2.8 4.0 5.0

+58.3%

+34.8%

Application design

Modeling & simulation

Prototyping & validation

Material selection

Composite/resin compatibility

Custom formulations

Mold filling analysis

Technical support

Process optimization

PROCESSING

1.866.POLYONE

www.polyone.com

Copyright © 2019, PolyOne Corporation. PolyOne makes no representations, guarantees, or warranties of any kind with respect to the information contained in this document about its

accuracy, suitability for particular applications, or the results obtained or obtainable using the information. Some of the information arises from laboratory work with small-scale equipment

which may not provide a reliable indication of performance or properties obtained or obtainable on larger-scale equipment. Values reported as “typical” or stated without a range do not

state minimum or maximum properties; consult your sales representative for property ranges and min/max specifications. Processing conditions can cause material properties to shift

from the values stated in the information. PolyOne makes no warranties or guarantees respecting suitability of either PolyOne’s products or the information for your process or end-use

application. You have the responsibility to conduct full-scale end-product performance testing to determine suitability in your application, and you assume all risk and liability arising from

your use of the information and/or use or handling of any product. POLYONE MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, IMPLIED WARRANTIES

OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, either with respect to the information or products reflected by the information. This literature shall NOT operate as

permission, recommendation, or inducement to practice any patented invention without permission of the patent owner.

MATERIALSMaterial selection is crucial to an application’s success. From resin formulations to composite matrix and fiber configurations, we can help you develop the combination that will meet your specific needs.

PROCESSINGWhile selecting the right material combination is critical, understanding how to process the materials is equally important. We can help you optimize your process—including via hands-on testing and trials at our Denver-based Composites Innovation Cell—to achieve targeted part performance.

DESIGNFinally, when creating a component that will meet your application requirements efficiently and economically, it’s important to consider design early in the development process. With a comprehensive approach combining application engineering and industrial design, our technical and design experts will work with you to accelerate your process from concept to finished component.

WHEN YOU WORK WITH POLYONEFrom concept to component, you can leverage PolyOne’s expertise throughout the development cycle in three key areas: Materials, Processing & Design

DES

IGN

MATERIALS

overmolding with polystrand™ continuous fiber reinforced

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