Bigger. Cleaner. Stronger. Lighter.
With the proprietary, patented TPF ThermoPlastic Flowforming™ process, complex, intricately detailed unitary parts with non-constant cross sections are possible at scales of up to 100 square feet in size and 200 pounds in weight. These parts benefit from higher strength and damage tolerance compared to other thermoformed components, and at lower weights and reduced lifecycle costs.



By specializing in thermoplastic polymers, the TPF ThermoPlastic Flowforming™ process also offers an environmentally friendly alternative to other processes, such as those using thermosetting polymers. Because thermosets require a chemical reaction to cure, they often produce volatile organic compounds (VOCs) and cannot be reprocessed or reformed once set. In contrast, TPF ThermoPlastic Flowforming™ components are 100% recyclable, non-toxic, and produce no VOCs during any stage of production, repair, or recycling.

Each cycle of the process begins with the selected virgin resin or recycled polymer, plus any number of additives, such as coloring, UV stabilizers, flame retardants, and fiber reinforcements. Precise ratios are automatically supplied through a gravimetric feed system. For enhanced mechanical properties, the composite matrix is blended for delivery at low pressure through a customized extrusion delivery system, preserving long fiber lengths and randomizing fiber orientations.

LRM’s unique dynamic die operates in concert with an automated trolley system, delivering the molten thermoplastic composite preferentially onto the mold surfaces that are shuttled below. The dynamic, computer-controlled die gates regulate the placement of material using a flow routine customized for each mold. The precision control provided by the dynamic die and trolley system provides near-net shape material placement in the mold, resulting in minimal material overflow and higher efficiencies.

The automated trolley transports the loaded mold into one of two 1,500-ton industrial compression presses containing the top half of the matched mold. The controlled compression of the composite ensures complete fill-out of the cavity for a detailed finish on even the largest parts. Compression forces result in up to 30% increase in strength over other thermoforming processes.

Following compression, a fully enclosed 6-axis robot safely removes the part for trimming, post-molding operations, final inspection, and shipping. All trimmed material is captured and reprocessed to further optimize efficiency.

For more information on TPF ThermoPlastic Flowforming™ technology, please contact us.

Applications
TPF ThermoPlastic Flowforming™ technology has enjoyed great success in numerous commercial and military applications. Recently, LRM Industries used this process in the manufacture of three prototype thermoplastic composite shelters for the US Air Force. Their stated goal is to begin replacing current metal ISO shelters with a thermoplastic alternative that is lighter and more durable, using advanced new manufacturing techniques.

The enhanced mechanical properties, low material costs, and low conversion costs of TPF ThermoPlastic Flowforming™ technology make it a strong contender for today’s multi-billion pound plastics market.