1. High Performance Thermoplastic Composites for Medical Applications
Cutting Dynamics
Avon OH
May 29, 2013

2. 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

3. Continuous Compression Molding
Process
Lay up tape in predetermined orientation
Process thru CCM flat machine- 24” wide max
Process thru CCM Shape Machine-5 x 5 sq max
Cut on 5 axis, WJ or Robot

4. CONTINUOUS COMPRESSION MOULDING MECHANICAL DEPICTION
2-step or 2D process
1-step or 1D process

5. Stamp Forming Process Description Material Layup- manual or FF
Continuous Compression Mold-Flat-24” wide
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

6. 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

7. 5 Axis Robotic Trimming

8. 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)

9. Prototype and Series Production of CCM Parts

10. Typical Weight Reduction Application
These typical parts could be made from one CCM then smaller parts removed then trimmed and formed.
lb alum
2.366 lb CCM
weight savings X 2 (RH + LH)
Use click-bond & delete rivets

11. 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

12. Injection Molding and Overmolding
Continuously Reinforced Components Can be Enhanced with Detailed Features by the Injection Overmolding Process
Enhanced Properties vs Injection Molding
Incorporation of Complex Features Without Subsequent Machining
Lower Cost
Metal Replacement Opportunities for Reduced Weight

13. 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

14. 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.

15. Thank you! Michael Favaloro Sales Manager
For more information, please contact:
Michael Favaloro
Sales Manager
Phone:
Bill Carson
President
Phone: Fax:
Cutting Dynamics, Inc.
980 Jaycox Road
Avon, OH 44011