MFG has developed a proprietary approach to DCPD. Characteristics of DCPD composites are virtual unbreakability, low density, ability to withstand very high impact, outstanding chemical resistance, high heat deflection temperatures, and good fatigue.
The resin is created using a catalyst (to open the dicyclo ring in the thermoplastic DCPD resin) mixed in either side of a 2-component mix (used 1:1). This mixture comes together in a high-pressure injection process, the ring opening occurs, and the thermoplastic becomes a thermoset in a matter of seconds. (The catalyst can be added into either side for the special injection process below.)
There is only one option for DCPD, a special injection process using two streams of thermoplastic resin. The catalyst used to open the dicyclo ring can be one of several. As soon as the components are simultaneous mixed/injected into the tool the part becomes a thermoset, yielding the part.
Typically no reinforcement is added. Patented products with fibers are available if reinforcements are needed, but that is rarely the case.
Special Design Considerations
Reinforcements are typically not used, but it is possible to locally thicken areas of the part that require more strengthening “in the tool”. Shrinkage of this material is in the 7% range and aluminum tools are standard. MFG’s Technical Design Guide for FRP Composite Products and Parts provides in-depth information for product designers. You can download it on the bottom of this page.
Produces a glossy, smooth surface that is paintable. Because of the shrinkage, MFG’s dedicated Design Center can provide guidance and assistance on the tool configuration.
This material does not typically have filler in the formulation. The cost of the material is typically about 2-3X that of thermoset polyester resins.
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