JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 53

Fig. 2: The hatch cover is shown directly above its final position on the float (left); the underside of the part shows its reinforced structure and attachment design features (right)

criterion in the design. The new hatch cover replaces earlier machined aluminium versions. The aluminium parts were too heavy, while these new ones weigh less than 900 g. They were also subject to dents and bending, and they cost too much – approximately five times the cost of the composite parts. The composite hatch covers have good corrosion resistance and can be easily replaced, which was another benefit Wipaire was seeking. Wipaire also considered a thermoset sheet moulding compound (SMC) with long fibres but the high material and development costs for that approach made PlastiComp a more logical choice. This project was also an opportunity to demonstrate PlastiComp’s part moulding capabilities, an area of business that the company is currently expanding. In addition, the proprietary Pushtrusion technology, which has

been installed in the technical development centre in Winona, means the company can rely on small volume production, preproduction or prototype manufacturing for selected customers. Since 2006, PlastiComp has been producing parts for customers who neither want nor need full-scale Pushtrusion technology in-house, but do want to benefit from parts produced with this advanced technology. This contract moulding was initially limited to injection moulding with Pushtrusion Direct In-line Compounding, but it is now offered with Pushtrusion D-GMT for compression moulding, the technology used to produce the hatch covers for Wipaire.

typical glass mat technology (GMT) sheet used for compression moulding. Pushtrusion units are custom-sized to the job and can be used with a wide variety of polymers (PP, PA, TPU, PBT, etc.) and fibres (E-glass, S-glass and carbon). The process gives processors the flexibility to customize their specific formula by fibre loading, polymer type and colour. They are not limited to standard GMT sheet offerings. Once the material has been selected, customers for D-GMT parts have several options: the part can be purchased directly from PlastiComp, or a part-sized preform can be purchased for moulding, or a Pushtrusion system can be used to mould parts in their own facility. In the case of the hatch covers, the team partnered with Wipaire from the start and is very pleased with both the results and the future potential. “You might say the sky is not the limit; it’s just the beginning.” More information: www.plasticomp.com Contact: rhonda@plasticomp.com

The D-GMT system produces hot charges of customized, precisely metered, long-fibre-reinforced compound that are Focus transferred to a compression press Since 1960, Wipaire has developed a full line of floats and immediately for all sizes of aircraft, from the Piper Cub to the de Havilland Twin Otter, as well as over 100 Supplemental pressed into finished parts, Type Certificates for a variety of useful aircraft eliminating the modifications.

No60 October 2010 / jec composites magazine

http://www.plasticomp.com

JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010