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CMT Learning Module 1 - Understanding HYTAC
- 1. Syntactic Foam for Plug Assist Module 1
- 2. Agenda 1.Introduction to CMT Materials 2.Definitions 3.HYTAC plug assist materials 4.Benefits of plug assist in thermoforming
- 3. Understanding CMT Materials Who we are: an innovative materials company What we do: design and develop innovative tooling materials for the thermoforming industry
- 4. What is Syntactic Foam? “A class of material with pre-formed hollow glass spheres held in a polyester or epoxy binder.”
- 5. What is a Plug Assist? A plug assist is a mechanical device used to aid or assist sheet stretching prior to total contact with the thermoform mold.
- 6. HYTAC® Plug Assist Material • HYTAC syntactic foam plug assist material is designed and tested for optimal performance in thermoforming applications. • There are currently 8 grades of HYTAC, each with specific properties and benefits • HYTAC is manufactured in sheets, rods and can be custom cast • HYTAC is sold and distributed around the world
- 7. HYTAC® Plug Assist Material
- 8. Understanding HYTAC® Thermoset Low cost Co-Polymer Thermoplastic Low CTE Low TC Ease of machining Excellent material distribution
- 9. • Good material distribution • Brittle & dusty FLX FLXT C1R • Excellent material distribution • Easiest to machine & polish Thermoplastic W WF WFT Co-Polymer Thermoset Understanding HYTAC® B1X XTL • Excellent material distribution • Most durable
- 11. Top 4 Reasons to Use a Plug Improve material distribution Reduce starting gauge Improve part clarity Improve cycle times
- 12. End of Module 1 www.cmtmaterials.com +1 508 226 3901
Editor's Notes
- Hello –I’m Conor Carlin with CMT Materials. This short presentation is the first in a new series of recorded sessions designed to help people understand the benefits of syntactic foam for thermoforming. Each session will be about 2-3 minutes in length and will cover a variety of topics ranging from basic material selection through to technical troubleshooting. We welcome your comments and feedback. Please visit our website at cmtmaterials.com for more information.
- Today’s presentation is an introduction to our company, our story and how we became the world’s leading producer and supplier of material specifically developed for plug-assist thermoforming. We will provide a high level overview of syntactic foam and how it evolved before introducing the different grades of HYTAC materials. Then we’ll wrap up with the benefits of using syntactic foam from the perspective of the end-user.
- CMT Materials was founded in 1998 by 3 materials engineers who had a passion for solving problems. Each of the founders had a background in advanced materials development. Their history, combined with extensive research and development efforts in tooling shops, thermoforming companies and machine builders resulted in a company that is focused on innovative tooling materials for thermoforming.
- The term “syntactic foam” first appeared in the 1960′s to describe a class of material with pre-formed hollow spheres as a main constituent. While syntactic foam is used in different applications, the grades used in thermoforming have evolved to create a valuable, highly stable material with ultra-low thermal conductivity. In addition, it can be machined to shape and it can be polished to a smooth surface to ensure optimal performance as a plug assist.
- A plug assist is a mechanical device used to aid or assist sheet stretching prior to total contact with the thermoform mold. The shape, surface condition and material make-up of the plug can all be modified to optimize the thermoforming process.
- HYTAC is the brand name for CMT’s syntactic foam materials. Unlike other materials used for plugs such as nylon or felt-covered wood, HYTAC was designed specifically for thermoforming. HTYAC can be matched with process or product requirements to ensure consistent parts that meet or exceed quality expectations. Many of the largest toolmakers and thermoformers around the world use HYTAC to produce consistent parts that meet or exceed quality expectations.
- Plug assist tooling helps stabilize the formingprocess.The use of HYTAC syntactic foam allows the tool designer to carry material to where it is needed most without marking the sheet. It aids material distribution and allows the thinnest possible starting gauge thickness, leading to material savings. Here are some examples of different types of plugs and plug materials.
- At a high level, HYTAC materials can be grouped into 3 categories. While there is some overlap, each grade is formulated to provide specific performance attributes.
- HYTAC materials are most easily categorized by the binder systems used. The entry level binder – thermoset epoxies – can be thought of as solid performers that provide good material distribution, though they are relatively brittle and generate dust during machining. The second category – co-polymers – represent a higher level of performance with enhanced material distribution and added qualities including ease of machining and polishing. The third category – thermoplastics – is designed to combine enhanced material distribution with durability and machinability. HTYAC-B1X is known throughout the thermoforming world as a leading plug assist material. We are pleased to say that our newest offering, HYTAC -XTL, surpasses B1X in terms of performance.
- We will spend more time on machining and polishing plugs in later modules, but this slide shows how each material type is machines and what kind of chip is generated during the machining process. Those with larger chips are more easily cleaned from machining centers.
- To end this module, we’ll leave you with the top 4 reasons why thermoformers use a plug assist.Improve Material DistributionImprove Part ClarityReduce Starting GaugeImprove Cycle Times
- Thank you for your attention. The next module will focus on material selection and how the plug interacts with the plastic sheet.