|
Metapor METAPOR
is manufactured in blocks of 500 x 500 x 400 mm and is sawed into slabs of
varying thicknesses. After the sawing process, the air permeability of the slab
surface is reduced due to partial closure of the pores. It is essential, to mill
the surface of the slab by removing approx. 0.5 mm (0.020"), providing
complete air -permeability.
| Slab Size (mm) |
Approx. Weight |
| 500 x 500 x 20 |
19lbs |
| 500 x 500 x 30 |
28lbs |
| 500 x 500 x 45 |
42lbs |
| 500 x 500 x 60 |
56lbs |
| 500 x 500 x 80 |
75lbs |
| 500 x 500 x 400 |
400lbs |
Storage
Store dry, protect against jolts and impacts. Avoid contact with grease and
fluids.
Machining
The machining properties of METAPOR are excellent and are comparable with rapid
machinable aluminium. METAPOR must be machined dry and should not be in
contact with any cooling liquids. In order to avoid any closure of pores,
sharp tools made of HSS or carbide with edge angles as for aluminium must be
used. It is recommended to use dust extraction.
Cutting speed of up to 1000 m/min can be applied.
The forward feed can be set up to 0.1mm/ tooth; in areas of thin walls the
forward feed should be reduced.
Grinding / Polishing
Grinding and polishing of the machined surfaces can be made by hand or with a
vibrating grinder . Use corundum paper with grains of 400 / 600 / 1200 in the
ascending order . METAPOR has to be polished dry and without any polishing
paste!
Cleaning of areas, contaminated with grease or
fluids
Thoroughly rub light dishwashing liquid into the affected area. Rinse with water
until cleared of foam. Heat METAPOR for approx. 3 hours (depending on the size)
in an oven. Temperature setting of 80°-100°C. (160° - 200° F)
Sealing of pores
In some cases, non air-permeable areas within a METAPOR tool are required. The
pores in those areas can be easily sealed with synthetic enamel, adhesive or
epoxy resin. Adhesive bonding
For METAPOR BF 100 AL, HD 100 AL and MACRO
products, we highly recommend to use CIBA ARALDITE 2014 for bonding. For
the high temperature material BF 210 AL, we recommend to use HYSOL EA 9394/C-2
from DEXTER Corp. In order to achieve best bonding results while minimizing
witness lines, pre-heating of METAPOR and adhesive to a temperature of 40-50°C
(100°-130° F) is recommended!
Mill
plane the surfaces
to be connected |
Cover
frame segments
with tape and apply
adhesive on both sides |
Press
parts together.
Allow adhesive to harden. |
 |
Effect of bonded
areas on
air
permeability |
 |
| Air
stream |
Vertical
bonding:
no effect |
Horizontal
bonding:
bond on a point basis or drill holes from below |
Using screws and threaded inserts with METAPOR
METAPOR tools can be fixed with particle board screws. Drill pilot holes with a
reduced diameter of approx. 1 mm (0.040") compared to the diameter of the
screws. Threaded inserts bonded into METAPOR segments, provide good durability
and strength.
Repair of METAPOR tool
In cases of small damage, the METAPOR tool can be repaired as follows: Damaged
area should be removed by creating a conical cavity; then a slightly oversized
METAPOR plug is machined; for larger plugs, some spots of adhesive should
be applied on contact surfaces; METAPOR plug is then pressfit into the conical
cavity and the surfaces are ground flat.
METAPOR thermoforming molds
Like conventional tools, Metapor molds are firmly mounted on the vacuum table.
In order to avoid any damage to the mold, it is essential to pre-heat the mold
to the required mold temperature (mold temperature depends on the forming
temperature of the plastic material).
Cooling of METAPOR molds
For molds, to be used as production tools, sufficient cooling has to be
provided. This can be achieved with different methods.
Flat molds, advantageously have to
be placed on a cooling plate; deep molds should be equipped with cooling lines
made out of a material with high thermal conductivity. The cooling lines should
be installed in parallel to the mold surface. Usually, the maximum distance to
the mold surface is approx. 30 - 40 mm (1" - 1.5"). When mounting the
cooling lines, a close contact to the METAPOR mold is necessary. Air gaps have
an isolation effect and need to be filled with a material of high thermal
conductivity.
The air permeability of the entire surface of
METAPOR tools offers very efficient cooling, if compressed air of up to 5 bar
(70 PSI) is blown through the METAPOR mold between the thermoforming cycles.
Air distribution
Air distribution channels on the bottom of the mold have to be provided for
perfect thermoforms. The following sketches show the most common procedures. Air
distribution channels, machined into a METAPOR mold, could look as follows:
Size of mold: 300 x 400 x 40mm (12" x
16" x 1.5")
Width of distribution channel: 15 mm (0.600")
Depth of channel: 5 mm (0.200")
Distance from channel center to channel center: 50mm (2").
The individual design depends on size and geometry of the mold.
| Distance holder or
distribution channels on the base plate. |
Distribution
channels milled into METAPOR |
Design of a hollow METAPOR mold
Hollow forming tools can be rapidly and securely manufactured at low cost in
using segments of METAPOR slabs. The individual segments can be connected by
bonding or screwing. (See also bonding and screwing guidelines)
Construction of hollow mold
Metapor BF 100 AL - Physical properties at
20°C
| Property |
Standard |
Units |
Value |
| Density |
|
g/cm3 |
1.8 |
| Shore hardness D |
DIN 53505 |
|
81 |
| Flexural strength |
DIN 53452 |
N/mm2 |
56 |
| E module |
DIN 53457-B3 |
N/mm2 |
9000 |
| Impact strength |
DIN 53453 |
kJ/m2 |
14 |
| Coefficient of thermal expansion
25-125°C |
DIN 53752 |
°C-1 x 10-6 |
30.4 |
| Heat conductivity: at 100°C |
DIN 52612 |
Wm-1 °C-1 |
19.1 |
| Dimensional stability according
Martens |
DIN 53462 |
°C |
108 |
| Mean pore diameter |
|
mm |
15 |
| Total porosity |
|
% |
15 |
Air flow rates
The numbers are average values for calculating air consumption for
overpressure or underpressure applications. Specifications are in liter per
minute per cm2.
| Pressure
difference in bar |
Plate
thickness in mm |
| 10 |
15 |
20 |
25 |
30 |
40 |
60 |
100 |
| 0.2 |
0.39 |
0.32 |
0.28 |
0.24 |
0.21 |
0.17 |
0.10 |
0.02 |
| 0.3 |
0.47 |
0.39 |
0.34 |
0.30 |
0.27 |
0.22 |
0.14 |
0.05 |
| 0.4 |
0.55 |
0.47 |
0.41 |
0.36 |
0.32 |
0.26 |
0.18 |
0.07 |
| 0.5 |
0.63 |
0.53 |
0.47 |
0.42 |
0.38 |
0.31 |
0.22 |
0.10 |
| 0.6 |
0.71 |
0.60 |
0.53 |
0.47 |
0.43 |
0.36 |
0.25 |
0.12 |
| 0.7 |
0.78 |
0.67 |
0.59 |
0.53 |
0.48 |
0.40 |
0.29 |
0.15 |
| 0.8 |
0.86 |
0.74 |
0.65 |
0.59 |
0.53 |
0.45 |
0.33 |
0.17 |
| 0.9 |
0.94 |
0.81 |
0.71 |
0.64 |
0.58 |
0.49 |
0.36 |
0.20 |
| 1.0 |
1.01 |
0.87 |
0.77 |
0.70 |
0.64 |
0.54 |
0.40 |
0.22 |
| 2.0 |
1.72 |
1.50 |
1.34 |
1.22 |
1.12 |
0.96 |
0.74 |
0.46 |
| 3.0 |
2.34 |
2.05 |
1.84 |
1.68 |
1.55 |
1.34 |
1.05 |
0.68 |
| 4.0 |
2.80 |
2.53 |
2.28 |
2.09 |
1.93 |
1.68 |
1.33 |
0.89 |
| 5.0 |
3.34 |
2.94 |
2.66 |
2.44 |
2.26 |
1.98 |
1.58 |
1.08 |
| 6.0 |
3.71 |
3.28 |
2.97 |
2.74 |
2.54 |
2.24 |
1.80 |
1.26 |
Metapor HD 100 AL - Physical properties at 20°C
| Property |
Standard |
Units |
Value |
| Density |
|
g/cm3 |
1.9 |
| Shore hardness D |
DIN 53505 |
|
81 |
| Flexural strength |
DIN 53452 |
N/mm2 |
43.6 |
| E module |
DIN 53457-B3 |
N/mm2 |
9200 |
| Impact strength |
DIN 53453 |
kJ/m2 |
11 |
| Coefficient of thermal expansion
25-125°C |
DIN 53752 |
°C-1 x 10-6 |
36 |
| Heat conductivity: at 100°C |
DIN 52612 |
Wm-1 °C-1 |
20.5 |
| Dimensional stability according
Martens |
DIN 53462 |
°C |
108 |
| Mean pore diameter |
|
mm |
12 |
| Total porosity |
|
% |
16 |
Air flow rates
The numbers are average values for calculating air consumption for
overpressure or underpressure applications. Specifications are in liter per
minute per cm2.
| Pressure
difference in bar |
Plate
thickness in mm |
| 10 |
15 |
20 |
25 |
30 |
40 |
60 |
100 |
| 0.2 |
0.21 |
0.17 |
0.11 |
0.09 |
0.07 |
0.06 |
0.04 |
0.01 |
| 0.3 |
0.25 |
0.21 |
0.13 |
0.12 |
0.09 |
0.07 |
0.05 |
0.02 |
| 0.4 |
0.29 |
0.25 |
0.16 |
0.14 |
0.11 |
0.09 |
0.06 |
0.03 |
| 0.5 |
0.33 |
0.28 |
0.18 |
0.16 |
0.13 |
0.11 |
0.07 |
0.03 |
| 0.6 |
0.38 |
0.32 |
0.20 |
0.18 |
0.15 |
0.12 |
0.09 |
0.04 |
| 0.7 |
0.42 |
0.36 |
0.23 |
0.20 |
0.16 |
0.14 |
0.10 |
0.05 |
| 0.8 |
0.46 |
0.39 |
0.25 |
0.23 |
0.18 |
0.15 |
0.11 |
0.06 |
| 0.9 |
0.50 |
0.43 |
0.27 |
0.25 |
0.20 |
0.17 |
0.12 |
0.07 |
| 1.0 |
0.54 |
0.46 |
0.30 |
0.27 |
0.22 |
0.18 |
0.14 |
0.08 |
| 2.0 |
0.91 |
0.80 |
0.51 |
0.47 |
0.38 |
0.33 |
0.25 |
0.16 |
| 3.0 |
1.24 |
1.09 |
0.71 |
0.64 |
0.53 |
0.46 |
0.36 |
0.23 |
| 4.0 |
1.53 |
1.34 |
0.88 |
0.80 |
0.66 |
0.57 |
0.45 |
0.30 |
| 5.0 |
1.77 |
1.56 |
1.02 |
0.94 |
0.77 |
0.67 |
0.54 |
0.37 |
| 6.0 |
1.97 |
1.74 |
1.14 |
1.05 |
0.86 |
0.76 |
0.61 |
0.43 |
Metapor HD 210 AL - Physical properties at 20°C
| Property |
Standard |
Units |
Value |
| Density |
|
g/cm3 |
1.9 |
| Shore hardness D |
DIN 53505 |
|
82 |
| Flexural strength |
DIN 53452 |
N/mm2 |
43 |
| E module |
DIN 53457-B3 |
N/mm2 |
10800 |
| Impact strength |
DIN 53453 |
kJ/m2 |
11 |
| Coefficient of thermal expansion
25-125°C |
DIN 53752 |
°C-1 x 10-6 |
32 |
| Heat conductivity: at 100°C |
DIN 52612 |
Wm-1 °C-1 |
19 |
| Dimensional stability according
Martens |
DIN 53462 |
°C |
210 |
| Mean pore diameter |
|
mm |
12 |
| Total porosity |
|
% |
16 |
Air flow rates
The numbers are average values for calculating air consumption for
overpressure or underpressure applications. Specification in liter per minute
per cm2.
| Pressure
difference in bar |
Plate
thickness in mm |
| 10 |
15 |
20 |
25 |
30 |
40 |
60 |
100 |
| 0.2 |
0.21 |
0.17 |
0.11 |
0.09 |
0.07 |
0.06 |
0.04 |
0.01 |
| 0.3 |
0.25 |
0.21 |
0.13 |
0.12 |
0.09 |
0.07 |
0.05 |
0.02 |
| 0.4 |
0.29 |
0.25 |
0.16 |
0.14 |
0.11 |
0.09 |
0.06 |
0.03 |
| 0.5 |
0.33 |
0.28 |
0.18 |
0.16 |
0.13 |
0.11 |
0.07 |
0.03 |
| 0.6 |
0.38 |
0.32 |
0.20 |
0.18 |
0.15 |
0.12 |
0.09 |
0.04 |
| 0.7 |
0.42 |
0.36 |
0.23 |
0.20 |
0.16 |
0.14 |
0.10 |
0.05 |
| 0.8 |
0.46 |
0.39 |
0.25 |
0.23 |
0.18 |
0.15 |
0.11 |
0.06 |
| 0.9 |
0.50 |
0.43 |
0.27 |
0.25 |
0.20 |
0.17 |
0.12 |
0.07 |
| 1.0 |
0.54 |
0.46 |
0.30 |
0.27 |
0.22 |
0.18 |
0.14 |
0.08 |
| 2.0 |
0.91 |
0.80 |
0.51 |
0.47 |
0.38 |
0.33 |
0.25 |
0.16 |
| 3.0 |
1.24 |
1.09 |
0.71 |
0.64 |
0.53 |
0.46 |
0.36 |
0.23 |
| 4.0 |
1.53 |
1.34 |
0.88 |
0.80 |
0.66 |
0.57 |
0.45 |
0.30 |
| 5.0 |
1.77 |
1.56 |
1.02 |
0.94 |
0.77 |
0.67 |
0.54 |
0.37 |
| 6.0 |
1.97 |
1.74 |
1.14 |
1.05 |
0.86 |
0.76 |
0.61 |
0.43 |
Metapor = High Quality Reproduction! |
Faster air evacuation! |
6077 Ashley Ct.,
Cincinnati, OH 45242
Ph: (513) 235-5131 / Fax : (513) 793-7212
e-mail : RBowen@MoldersWorld.com
Web: www.MoldersWorld.com
|
