Gusmer, Compcast teaming up in nylon
Gusmer Corp. of Lakewood, N.J., best known as a supplier of polyurethane machinery, has teamed up with Compcast Technologies LLC of Bernegat Light, N.J., to create a machine that actually polymerizes nylon 6 parts and casts them into fiber-reinforced parts, all in a single operation.
The new technology is called Compcasting. Gusmer is billing the process as a much less-expensive and faster alternative to injection molding, to do rapid prototyping and make production parts in quantities up to 1 million or 2 million. Fiber-reinforced nylon is used widely in the automotive industry for parts such as intake manifolds, valve covers, water pumps, radiator fins and fan shrouds.
Compcast Technologies owns the technology and licenses it to manufacturing companies. Gusmer builds the equipment.
Compcasting uses rapid tooling, instead of machining injection molds, dramatically cutting costs, the companies said. The data goes directly from a computer-aided-design file to a fiber-reinforced nylon 6 structural production part in just one or two days.
Here's how it works: A pattern is made using stereolithography, with materials traditionally used for cast urethane parts. Lost-core technologies also can be used. Next, a Gusmer RP-10 dispensing machine mixes caprolactam, a monomer used to make nylon 6, with an activating agent. The resulting slurry is heated to 284°-302° F, then the glass-fiber reinforcement is mixed in via the machine's agitator.
The catalyst is dispensed from a separately heated tank, then automatically injected in the right proportion into the stream of fiber-reinforced caprolactam just before it enters the mold. As the materials are dispensed, the mixture thickens to a denser slurry. The Gusmer RP-10 machine dispenses the nylon directly into a mold that has been preheated to the same temperature as the material.
The resin polymerizes into a structural part within seconds.
Contact Gusmer at tel. (732) 901-2752, fax (723) 905-8968; e-mail [email protected]
Lawton introduces compression press
C.A. Lawton Co. of Green Bay, Wis., introduced its 700-ton Lawton Advanced Thermoset compression molding press, for molding highly filled cross-linked resins with very fast cure times.
Cure times for the machine range from 10-12 seconds. The machine boasts exceptionally fast pressing speeds, up to 175 inches per minute, according to Lawton. The robust, rigid moving and stationary plates are designed to limit diagonal deflection to less than 0.001 inch per foot.
A pre-compressed tonnage ram hydraulic circuit delivers ``bumpless'' transition from rapid close to pressing stages.
Tel. (800) 842-6888, fax (920) 436-7630.
Harrel roll stack meets safety rules
Harrel Inc. of Norwalk, Conn., said its redesigned sheet roll stack is tailored to meet new safety standards, by quickly opening the nip opening between the rolls by a 4-inch gap within three seconds of tripping an emergency release.
The standard is B151.20, 1999, under the American National Standards Institute and the Society of the Plastics Industry Inc. Extruder maker Harrel of East Norwalk, Conn., said the new standard became mandatory on all new and rebuilt equipment after August 2001, and all existing equipment in the field after August 2002.
The company said the nip opening on the chill roll stack is the most dramatic change. Most roll stacks now in use can open to 1 or 11/2 inches. Harrel said most roll stacks in the field will have to be replaced or completely rebuilt to comply with the standard.
Harrel said sometimes it is possible to salvage existing rolls that are in good condition, and build them into a new roll stack frame.
The three chill rolls account for at least 30 percent of the total cost of the roll stack, the company said.
Tel. (203) 866-2573, fax (203) 866-1483, e-mail [email protected]
New Novapax model offers four stations
Novapax Maschinenbau GmbH of Leer, Germany, has dropped its custom-made machines for processing plastic and rubber, and will concentrate on an injection blow molding machine.
Novapax also has introduced a four-station new IBM model, an NSB 320 press that has 36 tons of clamping force. The company said the press is an economical machine for producing small bottles and jars.
Unlike three-station machines, Novapax claims the additional fourth conditioning system allows for more versatile and stable molding.
Contact Novapax through Innovative Blow Molding, tel. (609) 567-0457, e-mail [email protected] comm.net.
Battenfeld's center running 7-layer line
Battenfeld Gloucester Engineering Co. Inc. has completed the seven-layer blown film line at its technical center in Gloucester, Mass.
The new line includes the company's Contracool extruders, automatic profile control, a model 1008D winder and Extrol microprocessor control. It also features the UltraCool air ring.
The center also has a three-layer blown film line and a five-layer sheet line.
Tel. (978) 281-1800, fax (978) 282-9111, e-mail [email protected]
Wayne customizes substitute extruders
Wayne Machine & Die Co. of Totowa, N.J., said customers can replace old extruders with customized new machines, through its Direct OEM Replacement line of large extruders.
The machines come in screw diameters of 31/2, 41/2, 6 and 8 inches.
Wayne customizes the machines to match exactly overall outside dimensions, hopper locations, center distances, power drop and utility connections, vent stack location, barrel flange and screw design.
The company said exact matching avoids problems processors may face when forced to replace a large extruder built decades ago by a company now out of business. Wayne conducts a comprehensive review of the existing machine and location in the plant, then designs the new machine.
A large extruder can be replaced in less than one day of installation time.
Wayne Machine also accepts trade-ins, so customers don't have the headache of disposing of the spent extruder.
Tel. (973) 256-7374, fax (973) 256-1778, e-mail [email protected]