High
Performance Thermoplastic
Composites for Medical
Applications
Cutting Dynamics
Avon OH
May 29, 2013
Why Thermoplastic Composites?
• High strength, stiffness, lower weight vs metallic components
• Maintains high precision tolerances through numerous autoclave
sterilizations
• Radiolucent
• Tough, durable, excellent fatigue resistance
• Shape has the potential to be tailored on site if needed
• Green, recyclable product
• Excellent chemical resistance
Continuous Compression Molding
• Process
o Lay up tape in
predetermined
orientation
o Process thru CCM
flat machine- 24”
wide max
o Process thru CCM
Shape Machine-5 x 5
sq max
• Cut on 5 axis,
WJ or Robot
CONTINUOUS COMPRESSION MOULDING MECHANICAL DEPICTION
1-step or 1D process
2-step or 2D process
Stamp Forming
• Process Description
o Material Layup- manual or FF
o Continuous Compression
Mold-Flat-24” wide
o Stamp Form in Press- 40” x 48”
• Trim on 5 axis WJ or machine
Type Lay-up of multiaxial panels
• Full automatic process control
• Maximum part size 40" x 40"
• Maximum speed 5 minutes/part
• Maximum thickness not limited
• Status in Service
3-Dimensional Stamp Forming Process
• Full automatic process control
• Nominal compression force
4000 kN
• Maximum width 40"
• Maximum part size 28" x 40"
• Maximum speed 5
minutes/part
• Maximum temperature 752 °F
• Maximum thickness 0.2"
• Capacity 3-shift 8,500
parts/year
• (5 minutes/part)
• Status in Service
Production unit for 2D and 3D stamp forming
Medium parts
5 Axis Robotic Trimming
Profile Machine
• Maximum width 4" (100
mm)
• Maximum Cross section
4" x 4" (100x100 mm)
• Maximum feed 150 ft/h
(30 m/h)
• Maximum temperature
770 °F (410 °C)
• Maximum thickness
0.4"(10 mm)
Prototype and Series Production of CCM Parts
Typical Weight Reduction Application
• These typical parts could be made from one CCM then smaller parts
removed then trimmed and formed.
• 4.1926 lb alum
• 2.366 lb CCM
• 1.8266 weight savings X 2 (RH + LH) 3.6532
• Use click-bond & delete rivets
3D Molded Shapes
• Extrusion of IM7 reclaimed and Pure
PPS
• Fibers are Random- ½” to 1” long
• 40% Fiber, 60% PPS
• 70-80% of strength of uni- tape
• Add unidirectional tape in areas of
high stress for additional strength
Injection Molding and Overmolding
Continuously Reinforced Components
Can be Enhanced with Detailed
Features by the Injection Overmolding
Process
o Enhanced Properties vs Injection
Molding
o Incorporation of Complex Features
Without Subsequent Machining
o Lower Cost
o Metal Replacement Opportunities for
Reduced Weight
Injection Molding Properties
• Metal-like Properties Can be Achieved with Novel TP Matrix
Material
Tensile Strength
(ksi)
Density (g/cc)
Steel
58
7.8
Standard PES
13.6
1.35
30% GF PES
25
1.58
CDI Modified PPS
40
• Weight and cost reductions vs metal and compression molded parts
Summary
 Thermoplastic Composites are demonstrated, high
performance materials for medical applications
• Lightweight, high performance radiolucent material
• Maintains precision tolerances through numerous
sterilizations
• High temperature usage
• Wide variety of forms available
 We are interested in working on support and development
of medical applications.
Thank you!
For more information, please contact:
Michael Favaloro
Sales Manager
mfavaloro@cuttingdynamics.com
Phone: 978-270-6011
Bill Carson
President
bcarson@cuttingdynamics.com
Phone: 440-249-4165 Fax: 440-937-4742
Cutting Dynamics, Inc.
980 Jaycox Road
Avon, OH 44011