PlastiComp
PlastiComp, a global leader in long fiber thermoplastic (LFT) materials and technologies, has announced the expansion of its Complēt LFT composite pellet product line to include drop-in replacements for die-cast magnesium.
The new LFT products duplicate both the mechanical and electrical properties of magnesium in injection molding or extrusion materials that offer up to 40 per cent reductions in weight.
“Structurally, long fibre reinforced composites have a history of successfully being used to replace metals, such as aluminum, because they offer weight savings and easier fabrication which provide considerable cost reductions," said Raj Mathur, PhD, Vice-President of Technology at PlastiComp.
"Where composites have previously fallen short is in meeting the combination of both structural and electrical characteristics of metals. It is common in the consumer electronics and automotive industries to use metals like magnesium for their stiffness and EMI shielding properties. Now, PlastiComp is able to offer LFT drop-in substitutes that allow these types of metal applications to be converted to long fibre."
PlastiComp’s new LFT composites match the mechanical performance of pressure die-cast magnesium and aluminum with tensile modulus values up to 42,000 MPa. On the electrical side, they offer surface resistivity values down to 0.2 ohm sq and EMI shielding capabilities in the 60-80 dB range depending on wall section thickness.
Mathur explained: "Even though our new materials contain both long fibre reinforcement and nano fillers to achieve magnesium substitution properties, they mould extremely well. PlastiComp has already successfully demonstrated commercial applications, with cross sections in the 0.7 to 1 mm range, which were injection moulded without any difficulty using these LFT composites.
"Microstructural characterisation showed a conductive network of intertwined carbon fibers and uniform dispersion of the nano fillers throughout the parts."
The combination of mechanical and electrical properties provided in these new LFT composites are achievable in a wide range of polymers from commodity to engineering resins based on performance requirements and price sensitivity of applications.
In addition to hand-held devices and peripherals in the consumer electronics industry, PlastiComp’s new magnesium substitution LFT composites can also replace metal profile extruded frames within the automotive industry.
As a vertical, full service long fibre compounder, PlastiComp provides design and analysis services, composite pellet manufacturing, as well as injection molding or extrusion when needed. PlastiComp routinely partners with OEMs on new product development programs and uses finite element method and mould flow analysis to ensure strength and stiffness performance are not compromised when metal applications are converted to long fibre or designs are modified to reduce mass or increase functionality."