Differential Pressure Molding is a low-cost, low-pressure, compression-molding process with low energy requirements that enables sheet-form composites to be shaped and optionally bonded to a face material/skin in a single process step.  The process can bring significant benefits to programs that require a few-hundred to a few-hundred-thousand parts annually,

The process was developed to reduce the cost of tooling and capital equipment for low-to-medium production volumes. At such volumes, a DPM press and tool costs are: 

  • 50% less than equipment for other low-volume processes (e.g. thermostamping / low-pressure compression molding, thermoforming, and vacuum forming), and
  • 75% less than equipment for high-volume processes (e.g. high-speed compression molding, injection molding, etc.). 

Versus other low-pressure thermostamping, compression molding, or thermoforming processes, DPM tooling is more cost effective on low-to-medium production volumes.  In fact, the relative simplicity and low-cost of DPM tooling and capital equipment makes it ideal for use at remote manufacturing sites in emerging markets, or for manufacturing operations that desire to reduce their carbon footprint. 

Because DPM tooling can be designed and produced quickly and at low cost, it also is an excellent process for concept prove-out and prototyping parts for DPM and other compression processes.  Or it can produce parts for programs with very-short production runs.

Owing to the versatility of this process, DPM is the lowest cost, most flexible compression molding process commercially available to manufacturers of composite components.