1. Injection Moldable Metal Alloys
Xyloy™
Injection Moldable Metal Alloys

2. Bringing Design Freedom and Parts Consolidation to Metals
Xyloy™ Injection Moldable Metal Alloys
Bringing Design Freedom
and Parts Consolidation to Metals

3. Xyloy™ Injection Moldable Metal Alloys
Topics
Xyloy IS and IS NOTs
Manufacturing Steps
Material Properties
Markets & Case Studies
Compliance and Sustainability

4. Xyloy™ Injection Moldable Metal IS NOT…
Xyloy injection moldable metal IS NOT metal or powder injection molding (MIM/PIM)…

5. Xyloy™ Injection Moldable Metal IS NOT…
Xyloy injection moldable metal IS NOT metal filled plastic…

6. Xyloy™ Injection Moldable Metal IS NOT…
Xyloy injection moldable metal IS NOT thixomolding…

7. Xyloy™ Injection Moldable Metal IS NOT…
Xyloy injection moldable metal IS NOT die casting…

8. Xyloy™ Injection Moldable Metal IS…
Xyloy injection moldable metal IS injection molding of non-ferrous alloys on plastic injection molding equipment with conventional molds

9. Xyloy™ Injection Moldable Metal IS…
Xyloy injection moldable metal IS for OEMs with captive injection molding who want to bring metal part supply in-house

10. Xyloy™ Injection Moldable Metal IS…
Xyloy injection moldable metal IS for custom injection molders who want to offer plastic AND metal parts to OEMs and component manufacturers

11. Xyloy™ Injection Moldable Metal Alloys
Manufacturing Steps
Pellets
Tooling
Injection Molding
Part Finishes (optional)

12. Xyloy™ and Plastic PELLETS Pellets and feeding systems same as plastic

13. Xyloy™ and Plastic TOOLING
Same Tool – Same Part – Different Properties

14. Xyloy™ and Plastic INJECTION MOLDING
Electric or Hydraulic Machine Modifications
Software temperature limits
Dedicated screw and barrel
Robust heater bands, thermocouples, wiring

15. Xyloy™ Injection Moldable Metal Coatings, Conversions & Finishes
A variety of coatings, conversions and finishes are possible for meeting aesthetic, chemical, and corrosion resistance requirements
Surface texturing
Conversions (phosphate, chromate)
E-coat
Powder coat (polyester, epoxy)
colors
textures
Paint
Plating (copper, nickel, chrome)
Depositions

16. Xyloy™ Injection Moldable Metal Alloys
Xyloy M950 Properties
Xyloy™ M950 Metric English
Ultimate Tensile Strength MPa 47 kpsi
Yield Strength MPa 36 kpsi
Elongation at Break 2% 2%
Modulus of Elasticity 90 GPa kpsi
Density g/cc lb/in3
Thermal Conductivity W/mK 830 BTUin/hrft²°F
Specific Heat Capacity J/g°C 0.1 BTU/lb°F
Mold Shrinkage % 0.5%

17. Xyloy™ Injection Moldable Metal Xyloy M950 and Die Casting Alloys
M A380(Al) ZA3(Zn) AZ91D(Mg)
Ultimate Tensile Strength (MPa)
Elastic Modulus (GPa)
Density (g/cc)
Electrical Conductivity (% IACS)
Thermal Conductivity (W/mK)

18. Xyloy™ Injection Moldable Metal Alloys
Market Segments
                                          
Aerospace
Automotive
Computer/IT
Consumer
Electrical/Electronics
Health Care
Industrial

19. Xyloy™ Injection Moldable Metal Alloys Case Study – Valves & Controls
Problem: Reinforced engineering plastic failed due to mechanical load. Machined metal was 4X the price even with design changes.
Solution: Xyloy M950 molded in existing plastic tooling (3-plate). Low cost and high performance.

20. Xyloy™ Injection Moldable Metal Alloys
Case Study – Electronic Enclosure
Problem: Enclosure and thermal management for computer component. Features and dimensional tolerances required expensive machining.
Solution: Xyloy M950 molded in multi-cavity tooling. Molded-in features eliminate machining. High degree of flatness and dimensional accuracy.

21. Xyloy™ Regulatory Compliance Meets Current and Future Requirements
RoHS/WEEE compliant
RoHS/WEEE compliant finishes
Non-flammable
No halogen content
No low melting components
No heavy metals
No organics

22. Xyloy™ Injection Moldable Metal Alloys Sustainable / Recyclable
Ability to reuse regrind (runner, sprue)
Recycling via standard automobile and scrap metal recovery
True recyclability – infinitely recyclable
Fully restored properties versus degradation in polymers

23. Xyloy™ Injection Moldable Metal Alloys
Summary
Xyloy injection moldable metal alloys are molded on conventional plastic injection molding equipment to produce parts in high volumes
3-dimensional, net shape parts
No porosity, stronger than die cast
Can be used with existing tooling for plastics
Fast cycle times
Standard conversions, coatings and finishes
120 W/mK thermal conductivity
Minimal tool wear
Recyclable and sustainable

24. CoolPoly® Thermally Conductive Plastics
                                          
It’s been our pleasure to share with you some of Cool Polymers’ product technologies and applications. Thanks for you attention and we’d be pleased to respond to your questions and comments.
CoolPoly® Thermally Conductive Plastics
Xyloy™ Injection Moldable Metal Alloys
ISO 9001:2000 CERTIFIED