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Syntactic Foam for Plug Assist Module 2

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Agenda 1.Plug assist materials 2.Basic design concepts

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Why Use a Plug? Plug assist tooling helps stabilize the process Aids material distribution Allows thinnest possible starting gauge thickness Allows design detail Reduces cycle time Allows temperature optimization Aids part clarity Reduces overall process cost

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Materials for Consideration CategoryMaterialProsCons Historical/Traditional materials Wood, Felt, Wood/Felt, Wood/Foam, Foam or Felt covered forms Good Insulator Ease in machining Cost Durability/Dimensional stability Mark-off/Part repeatability Temp resistance AluminumTemp/process control Durability Surface characteristics Temp/process control Increased cycle time Process Cost Solid Polymers (traditional) Delrin, Nylon, Urethane,Cost & availability, Ease in machining / toughness Surface characteristics Durability/dimensional stability Poor insulators Temp resistance Solid Polymers (high performance) Polysulfone, PEIImproved temp resistance Toughness/strength Surface characteristics Durability/Micro- cracking/Crazing Poor Insulators Cost Engineered Plug AssistSyntactic foamExcellent insulator, Ease in machining Surface finish choices, Durable Learning curve for use Initial cost Many choices

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Physical Specifications Material Color Service Temperature Thermal ConductivityDensity Flexural Toughness (ASTM D790) Typical CNC Finish (in) CTE 0F0F 0C0CBTU/hr-ft- 0 FW/m 0 Klb/ft 3 kg/m 3 PsikPaRax10 -6 in/in 0 Fx10-6 m/m/ o C POM/Delrin 3501762.54.3881409 4785 Nylon 3501761.72.945720 60110 Aluminum - 1442491672675 2240 Oak 500? 0.10.1745720 59 Felt 0.040.069Substrate? Polysulfone 3001480.150.26781249 3156 PEI 3401710.100.17801281 3156 HYTAC-WWhite3501760.070.11436902.718.6542241 HYTAC-WFWhite4502320.110.19558804.732.4281832 HYTAC-WFTLight Green4252180.110.19609604.531242037 HYTAC-FLXPink3501760.070.11467407.652.4222342 HYTAC-FLXTDark Green3501760.10.17508057.249.6212036 HYTAC-C1RSlate Blue3501760.070.134674011.377.9223563 HYTAC-B1XLight Blue3501760.110.194572111.680393868 HYTAC-XTLMauve3501760.100.194572123.7163.432 58

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Understanding HYTAC Thermoset Co-Polymer Thermoplastic Low price Low CTE Low TC Ease of machining Excellent material distribution

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Understanding HYTAC Thermoset Co-Polymer Thermoplastic Low CTE Low TC Good matl distribution Brittle & dusty Excellent matl distribution Easiest to polish Excellent matl distribution Most durable

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Starting reference point: material safe means it is easy to remove material but impossible to put it back. Contact with plug and sheet: more contact = more carry. Basic Design Concepts

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Plug Design Possibilities* *Courtesy of Computer Designs, Inc. Whitehall, PA ORIGINAL DOGBONE 7 0 TAPER,.750 RAD. SIDES 3 0 TAPER 1.25R TOP 3 0 TAPER FULL TOP POCKET 3 0 TAPER.750 X 30 0 CHAMFER TOP

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Geometry Change Expected Effect. 3 0 TAPER.750 X 30 0 CHAMFER TOP 10 0 TAPER, HOLLOW FLOOR 3 0 TAPER 1.25R TOP

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Putting it all Together

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conor.c@cmtmaterials.com +1 508 226 3901 End of Module 2