https://www.avient.com/sites/default/files/2020-08/2020-composites-overmolding-overview.pdf
PROCESS OVERVIEW
Polystrand™ advanced thermoplastic composites
combine high strength, unidirectional, continuous
fibers with engineered thermoplastic resins to create
continuous fiber reinforced thermoplastic (CFRTP)
materials that feature exceptional strength-to-weight
ratio and high impact resistance.
Overmolding integrates Polystrand tapes and multi-
ply laminates into traditional thermoplastic molding
processes, such as injection and compression
molding, to create locally-reinforced, molded
components.
Overmolding with Polystrand™ Continuous Fiber
Reinforced Thermoplastic Composites
Processability Meets Performance
Overmolding with Polystrand
CFRTP can enhance the
performance of traditional
thermoplastics or enable metal
replacement in a wide range of
applications.
https://www.avient.com/sites/default/files/2020-10/composites-innovation-cell-program-bulletin_0.pdf
Thermoplastic Composite Innovation Cell
Injection and Compression Overmolding
HARNESS THE VERSATILITY
Are you working on a project that would benefit
from added reinforcement, reduced weight,
material reduction or part consolidation?
CAPABILITIES
• Prototype part sampling
• Tooling validation
• Process optimization
• Material configuration
• Application development support
• Laminate analysis
• Mechanical system analysis
• Resin flow with laminate inserts
• Finite Element Analysis
EQUIPMENT SPECIFICATIONS
Injection Molding
• Milacron-Fanuc Roboshot α-S15OiA with
4-axis robot
• Maximum shot capability at 171 grams
with a clamping for 198 tons
• Trial molds include a 4"x6" flat plaque
and a 3"x10" hat stiffening member
Compression Molding
• 450 ton down acting press
• 39" x 39" platen size
• Features automatic shuttle table with
IR preheat oven
Material Testing
• Instron Model 5982 Universal Testing System
with 100 kN load capacity
• AVE2 non-contacting video extensometer with
digital image correlation capability
• Environmental chamber that enables testing
from -150° to 350° C
PRODUCT BULLETIN
PROCESSABILITY
MEETS PERFORMANCE
Polystrand™ advanced thermoplastic
composites combine high strength,
unidirectional, continuous fibers with
engineered thermoplastic resins to create
continuous fiber reinforced thermoplastic
(CFRTP) materials that feature exceptional
strength-to-weight ratio and high impact
resistance.
Through injection or compression
overmolding, composite tapes and multi-
ply laminates are integrated into traditional
thermoplastic molding processes to create
locally-reinforced, molded components.
https://www.avient.com/sites/default/files/2021-01/virtual-reality-application-bulletin.pdf
A LOOK INTO THE FUTURE
VIRTUAL REALITY
APPLICATION BULLETIN
AESTHETIC APPEAL
Metallic and Custom Effects,
FDA-Approved Masterbatch Colorants
SOLUTION: Custom Polymer Colorants,
Pre-Colored Resins
WEARABLE COMFORT
Flexibility, Skin- Compatible Comfort,
Soft Touch, Heat Reduction
SOLUTION: Thermoplastic Elastomers
(TPEs), Thermoplastic Urethanes (TPUs),
Silicone, Nylon (PA)
FUNCTIONALITY
Impact Resistance,
Dimensional Stability, Strength
SOLUTION: Copolyester, PC/
Polyester Blends, Polycarbonate,
Styrenics
BETTER EXPERIENCES.
DURABILITY
Impact Strength, Rigid or Flexible Materials
SOLUTION: Thermoplastic Elastomers (TPEs),
Thermoplastic Urethanes (TPUs), Copolyester,
Polycarbonate, PC Blends, PMMA, Styrenics,
Nylon (PA), Silicone
SURFACE
PROTECTION
Performance Enhancing
Additives
SOLUTION: Antimicrobial
Additives, Scratch and Mar
Additives
ERGONOMICS
Soft Touch, Easy to Grip
SOLUTION: Thermoplastic
Elastomers (TPEs), Thermoplastic
Urethanes (TPUs), Silicone
TOUGHNESS
Impact Strength, Chemical
Resistance
SOLUTION: PC/Polyester
Blends, Copolyester
WEAR
PERFORMANCE
Wear-Resistance
SOLUTION: Polyester (PET),
Nylon (PA),
Acetal (POM)
DISCOVER.
https://www.avient.com/sites/default/files/2020-12/onflex-lo-hvac-flap-english.pdf
TIER 2 SUPPLIER
H V A C F L A P
• Eliminate post treatment heating of parts
to achieve required odor level
(≤3.0 VDA 270)
• Lowest VOC / FOG performance (VDA 278) at the same
compression set as previous material
• Reduced processing steps and lowered
energy costs for the molder
• Achieved targeted odor levels and met VOC
/ FOG performance and compression set
standards
OnFlex™ LO Thermoplastic Elastomer
WHY AVIENT?
https://www.avient.com/products/thermoplastic-elastomers/onflex-thermoplastic-elastomers
https://www.avient.com/sites/default/files/2020-10/2020-gravi-tech-design-guide-.pdf
KEY CHARACTERISTICS
The primary features and benefits
of Gravi-Tech formulations are:
• Customized density, offering a wide range of
specific gravities from 1.5 to 11 gm/cm3
• Broad modulus range, from very flexible to
very rigid grades
• Corrosion resistance, withstanding oxidation
for long-term use and benefit
• Chemical resistance, withstanding fuels, oils
and other harsh chemicals
Additional features include:
• Design flexibility and processing ease
• Good impact strength
• Elevated heat deflection temperature
6 Gravi-Tech Design Guide 7
CHAPTER 2 | PROCESS SETTINGS
Density Modified Formulations
Gravi-Tech™ polymer-metal composites are high-density materials developed as thermoplastic-based
alternatives to lead and other traditional metals.
These materials have been formulated using select metallic
fillers and engineered thermoplastic resins to have densities similar to actual metals, while also providing the
design flexibility and processing ease of conventional thermoplastics.
Types of Layout Designs
FIGURE 56 - Grid
FIGURE 58 - Radial
FIGURE 57 - Series
FIGURE 59 - Hybrid
48 Gravi-Tech
Mold Strength
When consulting how strong the mold needs
to be, there are two types of pressures it must
withstand: injection pressure and clamping
pressure.
https://www.avient.com/sites/default/files/2021-04/trilliant-hc8900-medical-device-housing-case-study.pdf
DEVICE
MANUFACTURER
M E D I C A L D E V I C E H O U S I N G
• Improved chemical resistance compared to PC/ABS,
PC/PET & COPE
• Flame retardant (FR) rating of V-1 at 0.75 mm
• Zero BPA & non-halogenated FR material
• Available in standard hospital grade pre-colors
• Provided a cost-effective material with superior
chemical resistance to traditional materials
• Formulated a medical-grade, semi-crystalline
blend to support regulatory testing and
approvals
• Demonstrated superior property retention and
crack resistance after exposure to hospital-
grade disinfectants, including Virex® Tb,
helping to extend the device life
Trilliant™ HC8900 Thermoplastics
KEY REQUIREMENTS
WHY AVIENT?
https://www.avient.com/products/engineered-polymer-formulations/chemical-corrosion-resistant-formulations/trilliant-hc-healthcare-thermoplastics
https://www.avient.com/sites/default/files/2022-05/Trilliant HC - OCD Microwells IVD Testing - Application Snapshot.pdf
Trilliant HC - OCD Microwells IVD Testing - Application Snapshot
ORTHO CLINICAL
DIAGNOSTICS
M I C R O W E L L S F O R I V D
D E V I C E
• PS-based material
• Strict TiO2 content/filling to secure accurate performance
• Material to be suitable and complaint with the IVDD/IVDR
standards
• Surface chemical performance essential for the application
• Worked in close collaboration with customer and
internal teams to fully understand and overcome
current material challenges
• Identified anomalies in existing formulation using
material science expertise and customized an
alternative formulation
• Enabled customer to improve processing
efficiency, reduce scrap rate and respond to the
increased market demand
Trilliant™ HC7410-5001 X4 thermoplastics in
white
KEY REQUIREMENTS
WHY AVIENT?
https://www.avient.com/products/engineered-polymer-formulations/chemical-corrosion-resistant-formulations/trilliant-hc-healthcare-thermoplastics
https://www.avient.com/sites/default/files/2020-08/case-study-lightweight-garden-hose.pdf
https://www.avient.com/products/thermoplastic-elastomers/versaflex-thermoplastic-elastomers
https://www.avient.com/sites/default/files/2020-07/versaflex-philips-avent-bottle-spanish.pdf
https://www.avient.com/products/thermoplastic-elastomers/versaflex-thermoplastic-elastomers
https://www.avient.com/sites/default/files/2020-07/onflex-lo-hvac-flap-spanish.pdf
https://www.avient.com/products/thermoplastic-elastomers/onflex-thermoplastic-elastomers