Engineering Materials

Engineering materials is a discussion led by Design News Contributing Materials Editor Doug Smock on important new developments and applications that affect mechanical design. Metals covered include all types of steel and nonferrous metals, in all shapes. Resins covered include nylons, polycarbonates, polysulfides, polyimides, and polybutylene terephthalate (PBT). Other materials covered include ceramics and rubber. Topics covered include materials enhancement, new applications, process technology, tooling, sustainability, and economic issues. Posts will include latest news from global events such as K 2007, the Alliance of Plastics Processors Annual Conference, the National Plastics Exposition, and the annual technical conference (ANTEC) of the Society of Plastics Engineers.

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Sunday, November 25, 2007

New Assembly Approach Boosts Thermoformable Sheet

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.

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