HighPerformance

ThermoplasticComposites for Medical

Applications

Cutting DynamicsAvon 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

• Processo 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 Costo 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 FavaloroSales Managermfavaloro@cuttingdynamics.comPhone: 978-270-6011

Bill CarsonPresident bcarson@cuttingdynamics.comPhone: 440-249-4165 Fax: 440-937-4742

Cutting Dynamics, Inc.980 Jaycox RoadAvon, OH 44011