I suggest Compression moulding with sheet moulding compound (SMC). We supply seats to the Jetski industry where they neeed high strength, impact resistence, light weight, modulus and thin cross sections. Are SMC fiberglass have these properties :
Flex Strength > 85,000 psi
Flex Modulus > 3.0 x 10 to the 6 psi
Tensile Strength > 50,000 psi
Tensile Modulus > 3.8 x 10 to the 6 psi
Impact, notched > 33
Compression strength > 42,000 PSI
moulding with harden steel match dies, good repeatability and fast cycle time. The SMC is also cost effective.
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We are developing a range of chairs with plastic shells (used with a variety of bases) for an international furniture brand. I am interested to hear from reps and engineers with suggestions of innovative advanced polymers. This will be a high quality modern range that will sell into top commercial fit-outs.
There is a pressure sensitive plastic parts product in the market. Check some of the product descriptions in the back of your subscriptions. Yes, hard copy does have a place. The product changes color as a result of pressure. You can use it to measure for similar pressure on the four corners (parallel) of the plattens whan a mould is installed. If you plattens are really off, call the <a href="http://www.injectionmoulding.org/4-tips-to-choose-an-injection-mould-manufacturer-in-china.html">injection mould manufacturer</a> service. Unless you do this type of repair work on a regular basis, leave to those who were trained for it.
The pressure sensitive plastic parts is one of the tools we provide to process and production engineers across several industries. The corners are a popular way of running the tests you're pertaining to. Some process engineers like to look at the planarity of the mould platens that might be giving them trouble like addressing flashing and parting line issues.
Although the real chemistry is in <a href="http://www.injectionmoulding.org/mould-making-company-selection-tips.html">mould making</a> the resin, there are still many challenges in setting up a compounding line. Back in the '70's there were a number of small companies that bought resin and just did the compounding, but I'm not sure you can do that for 30-40 MT per month. I had customers that used that much material in a week back then and they didn't want to set up a compounding line.
A lot of years ago now, Durez did a study on the sound dampening effects of phenolic vs metal. They used some of the facilities at SUNY Buffalo to conduct this work. It's really very interesting. I would think you could contact them about the study if you're interested in more detail. This work was initally done for the automotive industry as they have a considerable interest in noise reduction under the hood.