Powdertech Surface Science has developed a method for bonding metal to thermoplastic composite materials. It calls the method Powderbond. It’s a single-stage process and involves inserting powder-coated aluminum into a mold, together with polypropylene, and utilizing the customary composite curing cycle.
Powdertech employed Powderbond in the Ariel HyperCard project to bond glass fiber polypropylene to aluminum for the vehicle’s monocoque chassis. The work was part of the SOLMAC project, which the Niche Vehicle Network funded as one its Production Readiness projects. Innovate UK, OLEV and the APC also supported it.
Powderbond is a lean manufacturing process that required no surface preparation or activation period and just an energy-saving short curing cycle. A standard chassis consists of several hundred separate parts, welded and riveted together. By producing the aluminum-composite bonds within a mold, the amount of HyperCard Chassis parts are reduced by over 75%.
Powdertech further explained that bonding thermoplastics and metals in a single process offers remarkable design freedom. Multifaceted and complex shapes can be molded into the composite structure all while integrating high strength metal features. One could use the best lightweight materials for the job, wherever they are needed.
Ecomass Compounds are a line of patented, nontoxic, high-density thermoplastic composite materials that can be processed on conventional injection molding, compression molding, and extrusion equipment. Ecomass Compounds can be formulated using a variety of polymers and fillers to meet a wide range of customer requirements including:
• Density (up to 11.0 g/cc)
• Heat Deflection Temperature
• Tensile Strength
• Impact Strength
• Flexural Modulus
Ecomass Compounds also have applications in a variety of other products where lead and other heavy metals are currently used. Some of these include Lead Free Ammunition, Gamma Ray Shielding, Weighting and Balancing Applications, and Vibration Damping.
Ecomass Technologies is committed to developing, formulating, and producing the best possible composite materials to empower its customers to produce the best possible parts. While it is not an injection molder, it nonetheless helps its customers manage the injection molding process of parts made with its materials.
With Ecomass, there’s no need to utilize a qualified molder or wonder whether a molder can effectively run a new material. Ecomass’ skill, training, and over 15 years of experience provides it with an established network of injection molding partners with whom it has great working relationships. Such results in short lead times and lower costs.
Ecomass Compounds meet the RoHS Directive; do not contain lead or lead compounds; and, contain no materials the U.S. Department of Defense Listing of Toxic Chemicals, Hazardous Substances and Ozone Depleting Substances or the U.S. Environmental Protection Agency’s (EPA) Hazardous Substances Priority List considers toxic or hazardous.
If you have a special requirement, contact Ecomass Technologies via its RFQ Form at:
Or see its website at: http://www.ecomass.com
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