Deployment of the microcellular foam process by automobile manufacturers, system suppliers, and converters is changing the fundamental cost structure of, and creating cost-saving design alternatives for injection molded automotive components. With a payback period below 18 months, an average return of 300% to 400%, and net part savings of 10% to 25%, the investment in microcellular foam technology has a compelling financial justification. The ability to more consistently mold thinner, flatter, dimensionally improved parts through the microcellular foam process benefits the automotive sector spectrum ranging from electric and electronic components to engine compartment and fuel systems through safety and interior applications. Polymer manufacturers are creating additional value through microcellular foam application development and the design of some products especially for the microcellular foam molding process. New and simplified principles of mold and part design are being applied to capitalize on the longer flow lengths and lower clamp forces, mold temperatures, and cavity pressures associated with microcellular foam molding. Designing specifically for the microcellular foam process routinely results in lower mold costs, reduced component costs, and optimized component functionality. Hardware advances such as the SII SCF Delivery System, including the SII SCF Delivery Unit and SII Satellite, make the microcellular foam injection molding process more userftiendly and have furthered the economic benefit of the technology. Automotive components with high technical demands in part performance and/or processing benefit considerably from the microcellular foam injection molding process. Applied as a core plastics processing technology, the microcellular foam injection molding process is providing economic benefit across a broad automotive component landscape including thin-wall parts requiring tight tolerances and dimensional stability; components with large differences in thickness and diameters; painted components; in-mold decorated and labeled components using fabrics and films; insert-molded parts; and components with high flow length to wall thickness ratios.
How microcellular foam molding changes the cost structure of injection molded automotive components: a review of the process and automotive applications
Einfluß des mikrozellullaren Formschäumverfahrens auf die Kostenstruktur von Automobil-Spritzgussbauteilen: Ein Überblick über den Prozess und die Automobilanwendungen
2002
12 Seiten, 22 Bilder, 2 Tabellen, 5 Quellen
Conference paper
English
British Library Conference Proceedings | 2002
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