Tooling costs to make plastic bumpers and fascia can be reduced by a factor of five using a thermoformable sheet, which for the first time can now be laser welded. Fittings can be welded that allow attachment to cars. “In the past, it was impossible to fasten components to the thermoformed sheet in a cost-effective way,” comments Thilo Stier, innovation manager for A. Schulman, a plastic compounder based in Akron, OH. The main reason is that the visible surface of the sheet would show sink marks on the cosmetic surface.The solution is use of a black laser-absorbing layer to concentrate the heat zone on the area that is being welded. A fitting can be welded in two to three seconds, Stier says.
The new technology could put Invasion five-layer extruded thermoformable sheet on a fast track. Schulman introduced its Invision sheet product in 2006 and formed A. Schulman Invision, Inc., a wholly owned subsidiary. Schulman is building a new Invision plant in Findlay, OH. Sheet can be extruded in thicknesses ranging from 0.4 mm to 12 mm. Properties include good impact strength, UV stability and Class A surface, according to Stier.
How can automakers, aerospace contractors, and other OEMs get new metal alloys that are stronger, harder, and can survive ever higher temperatures? One way is to redesign their crystalline structures at the nanoscale and microscale.
Although a lot of the excitement about 3D printing and additive manufacturing surrounds its ability to make end-products and functional prototypes, some often ignored applications are the big improvements that can come by using it for tooling, jigs, and fixtures.
A fun and informative tour you can attend at the upcoming Design & Manufacturing Minneapolis, MD&M Minneapolis, and other events there, is the Materials Innovation Tour on Wednesday afternoon. I'll be leading it.
Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies.
You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived.
So if you can't attend live, attend at your convenience.