Plug Assist Materials
The family of plug assist materials has been designed and tested to ensure optimal performance with most thermoformed plastic materials.
General Purpose Syntactic Foam Plug Assist Materials:
. B1X 180°C Thermoplastic Syntactic
This light blue thermoplastic syntactic is considered by many to be the best plug material available. It machines without dust like a solid polymer, provides the heat transfer properties of a syntactic and allows for machining of fine detail. With more than 4x the flexural strength of standard thermoset syntactic foams B1X is highly durable in the most rugged thermoforming environments. Suitable for use with nearly all plastics, it is the ideal choice for optimized material distribution and long plug life. Thermoplastic binder system may be direct threaded for easy attachment to a plug base.
. FLX Tough, Flexible 180°C Copolymer Syntactic
This unique copolymer syntactic provides nearly 3x the toughness of standard thermoset syntactics yet machine with no dust and may be easily polished to a smooth surface. Ideal choice for opaque PP where complex, demanding geometries and consistent material distribution are needed across the tool. FLX is highly recommended for use with clear PET and provides uniform distribution of material at lower processing temperatures.
. FLXT Ultra Smooth-Surface , PTFE Impregnated Copolymer Syntactic
Combines the toughness and easy machining/polishing of the standard FLX formulation with PTFE impregnation for a long lasting, easy release surface finish. This product has become the material of choice when forming PP, multi-layer films, barrier plastics and other applications requiring high clarity and minimal scratching. FLXT replaces PEI, PEEK and other smooth surface, more expensive solid polymers.
. C1R High Durability Coploymer Syntactic with Enhanced Friction
High performance copolymer syntactic foam optimized for high flexural toughness and material distribution properties. The result is a plug material that may be easily machined and polished (without dust!) for optimal performance in use. It is suitable for use with nearly all plastics.
. W 180°C Thermoset Syntactic
Entry level syntactic foam for non-critical, short run applications. Provides low thermal conductivity for quick start-up times and good material distribution with most plastics. Like all thermoset epoxy syntactics, this material tends to be brittle in use.
Special Purpose Syntactic Foam Plug Assist Materials:
. WFT 215°C Thermoset Syntactic with PTFE for Improved Slip
This product incorporates PTFE directly into its syntactic structure to eliminate sticking and material build up on the plug surface. This light green material is a good choice for use with sticky materials and shorter run applications.
. LP Specially Formulated Dual Layer Syntactic for Large Plug Applications
When forming very large plugs, this system is used in place of the conventional process of bonding blocks or sheets. This unique approach eliminates problems associated with bonding markoff, exotherm cracking, shrinkage and mismatch materials. Most customers see a significant cost and weight reduction when compared to bonding techniques.
Machining and Processing Guides
Standard Size Chart