Harnessing the Power of Plastics

DPM Benefits & Opportunities

There are numerous benefits to Differential Pressure Molding, such as:

LOW COST

  • Compression molding capabilities at vacuum-forming prices;
  • Low tooling costs;
  • Significantly lower capital equipment costs;
  • Much smaller manufacturing footprint;
  • Ability to mold multiple parts (of different sizes and geometries) at the same time further reduce piece cost;
  • One-stop shopping: single-source for both tooling and process equipment;
  • Ideal for low-to-moderate volume production (<100,000 pieces annually);
  • Typical DPM process savings vs. compression molding:
    • Tooling costs are 50-75% lower,
    • Tooling turnaround is 50% faster,
    • Output per square foot is 2-4x higher, and
    • Owing to lower scrap rates, materials savings of 10% or more can be seen.

HIGHLY VERSATILE

  • Ability to mold both thermoplastic and thermoset sheetstock:
    • Monolithic sheet or sandwich-panel composites,
    • Reinforced or unreinforced materials,
    • Ability to consolidate multiple layers of materials to optimize perforamance, aesthetics, and cost;
  • Owing to minimal flow-forming of materials, able to co-mold / bond a decorative skin / covering in a single process step without tearing or distortion (reducing process steps and costs); 
  • Able to mold single large parts or numerous smaller parts (in a family tool); 
  • Press can be outfitted with several different molds and can process different materials and different part geometries at the same time; 
  • In-mold hand-placed slides allow demolding of parts with severe undercuts and better edge finishes, 
  • In-mold knife trimming eliminates the need for post-mold waterjet cutting, a large capital expense for low-volume production operations.

FAST-TO-MARKET PRODUCTION

  • Rapid tool fabrication (2 hours to 2 weeks);
  • Quick press build (6-12 weeks);
  • Facilitates pre-market validation of high-speed compression tooling in low-cost composite tools;
  • Ideal for rapid and low-cost concept proveout and design validation.

LOW ENERGY / GREEN MANUFACTURING

  • Much lower facility and process energy requirements for low-carbon-footprint manufacturing;
  • Excellent option for emerging markets and remote-site manufacturing;
  • Ability to eliminate many post-mold secondary operations;
  • Minimal post-mold trimming.

HIGH QUALITY, DEPENDABLE PROCESS

  • Fast-cycling process (30-90 seconds) with excellent repeatability and reproducibility (R&R) values;
  • Tooling changes can be made quickly and at low cost;
  • Low molding pressures reduce residual stresses and post-mold warpage.